Arctic_cat_2012_dvx_300_300_utility_service_manual Arctic Cat 2012 Dvx 300 Utility Service Manual

User Manual: arctic_cat_2012_dvx_300_300_utility_service_manual

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FOREWORD
TABLE OF CONTENTS

FOREWORD

This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2012 Arctic

Cat ATV 300 Utility/DVX 300. This manual is designed to aid service personnel in service-oriented applications.

This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to the

standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual

as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition.

The service technician should become familiar with the operation and construction of each component or system by

carefully studying this manual. This manual will assist the service technician in becoming more aware of and efficient

with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor.

All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize

important information. The symbol ! WARNING identifies personal safety-related information. Be sure to fol-

low the directive because it deals with the possibility of severe personal injury or even death. A CAUTION identi-

fies unsafe practices which may result in ATV-related damage. Follow the directive because it deals with the possibility

of damaging part or parts of the ATV. The symbol NOTE: identifies supplementary information worthy of particular

attention. The symbol  AT THIS POINT directs the technician to certain and specific procedures to promote

efficiency and to improve clarity.

At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs

used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic

Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.

All materials and specifications are subject to change without notice.

Keep this manual accessible in the shop area for reference.

Product Service and

Warranty Department

Arctic Cat Inc.

®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

SHAR

E OUR PASSION.

Manual

Service M

ervice

X 3

VX 300

DVX 3

DVX 300

300 Utility300 Utility

Utility

00 Uti

TABLE OF CONTENTS

General Information........................................................... 2

General Specifications.................................................. 2

Torque Specifications.................................................... 3

Torque Conversions (ft-lb/N-m)..................................... 4

Break-In Procedure ...................................................... 4

Gasoline - Oil - Lubricant.............................................. 4

Genuine Parts............................................................... 5

Preparation For Storage ............................................... 5

Preparation After Storage ............................................. 6

Periodic Maintenance/Tune-Up......................................... 7

Periodic Maintenance Chart ......................................... 7

Lubrication Points ......................................................... 8

Air Filter ........................................................................ 8

Valve/Tappet Clearance................................................ 8

Testing Engine Compression ........................................ 9

Spark Plug .................................................................... 9

Muffler/Spark Arrester ................................................ 10

Engine Oil - Filter........................................................ 10

Rear Drive Lubricant (Utility) ...................................... 11

Transmission Lubricant ............................................... 11

Drive Chain (DVX) ...................................................... 12

Driveshaft/Coupling (Utility) ........................................ 13

Nuts/Bolts/Cap Screws ............................................... 13

Headlight/Taillight- Brakelight ..................................... 13

Shift Lever................................................................... 13

Hydraulic Brake Systems............................................ 14

Auxiliary/Rear Hydraulic Brake ................................... 16

Burnishing Brake Pads ............................................... 18

Checking/Replacing V-Belt ......................................... 18

Engine/Transmission....................................................... 20

Removing Engine/ Transmission ................................ 21

Top-Side Components ................................................ 26

Removing Top-Side Components ............................... 26

Servicing Top-Side Components ................................ 28

Installing Top-Side Components ................................. 32

Left-Side Components................................................ 34

Removing Left-Side Components............................... 34

Servicing Left-Side Components ................................ 34

Installing Left-Side Components................................. 40

Right-Side Components ............................................. 41

Removing Right-Side Components ............................ 42

Servicing Right-Side Components.............................. 47

Installing Right-Side Components .............................. 54

Center Crankcase Components ................................. 55

Separating Crankcase Halves .................................... 55

Disassembling Crankcase Half................................... 55

Servicing Center Crankcase Components ................. 55

Assembling Crankcase Half........................................ 57

Joining Crankcase Halves .......................................... 57

Installing Engine/Transmission ................................... 57

Troubleshooting .......................................................... 61

Fuel/Lubrication/Cooling................................................. 64

Carburetor................................................................... 64

Throttle Cable Free-Play............................................. 68

Engine RPM (Idle) ...................................................... 68

Gas Tank..................................................................... 68

Gas Tank Valve........................................................... 69

Gas/Vent Hoses.......................................................... 69

Oil Flow Chart............................................................. 69

Oil Pump..................................................................... 70

Liquid Cooling System................................................ 70

Radiator.......................................................................70

Hoses/Thermostat.......................................................71

Fan ..............................................................................71

Water Pump ................................................................71

Troubleshooting ...........................................................72

Electrical System..............................................................73

RPM Limiter ................................................................73

Testing Electrical Components ....................................73

Electrical Connections.................................................73

Switches......................................................................73

Battery.........................................................................73

Brakelight Switch (Auxiliary)........................................74

Brakelight Switch (Handlebar Control) ........................74

Coolant Temperature and Cooling Fan Switches ........75

Fan Motor ....................................................................75

Fuse Block...................................................................75

Fuses ..........................................................................76

Ignition Coil .................................................................76

Indicator Lights (DVX) .................................................77

LCD Gauge Assembly.................................................77

Ignition Switch .............................................................78

Handlebar Control Switches........................................78

Magneto Coils .............................................................79

Starter Motor ...............................................................79

Starter Relay ...............................................................79

CDI Unit.......................................................................80

Regulator/Rectifier ......................................................80

Start-in-Gear Relay .....................................................80

Headlights ...................................................................81

Taillight - Brakelight .....................................................81

Ignition Timing.............................................................81

Troubleshooting ...........................................................82

Drive System.....................................................................84

Rear Drive Assembly Schematics ...............................84

Rear Drive Axle (DVX).................................................84

Rear Drive Axle (Utility)...............................................87

Troubleshooting Drive System.....................................96

Troubleshooting Brake System....................................96

Suspension .......................................................................97

Front and Rear Suspension Assembly Schematics ....97

Front Shock Absorbers................................................97

Rear Shock Absorber ..................................................98

Swing Arm...................................................................99

Front A-Arms .............................................................102

Wheels and Tires ......................................................104

Troubleshooting .........................................................105

Steering/Frame/Controls................................................106

Steering Post/Tie Rods .............................................106

Measuring/Adjusting Toe-In/Toe-Out.........................108

Body ..........................................................................108

Steering Post Cover/Instrument Pod .........................111

Front Brake Lever/Master Cylinder Assembly ...........111

Auxiliary Brake Pedal/Master Cylinder Assembly......112

Throttle Control .........................................................113

Troubleshooting .........................................................114

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

Note: To navigate through this manual, use the PAGE UP/PAGE DOWN buttons on the keyboard, click on the

Table of Contents bookmarks on the left side of the screen, or click the blue text below. To return to this page,

click the Manual Table of Contents button at the bottom of each page.

Click on the blue text to go.

General Information

NOTE: Some photographs and illustrations used in

this manual are used for clarity purposes only and

are not designed to depict actual conditions.

General Specifications

Specifications subject to change without notice.

CHASSIS DVX Utility

Dry Weight (approx) 192.8 kg (425 lb) 216 kg (477 lb)

Length (overall) 171.9 cm (67.7 in.) 187 cm (73.6 in.)

Height (overall) 113.5 cm (44.7 in.) 111.8 cm (44.0 in.)

Width (overall) 113.5 cm (44.7 in.) 105.1 cm (41.40 in.)

Suspension Travel (Front)

(Rear)

15.5 cm (6.1 in.)

16.5 cm (6.5 in.)

12.7 cm (5.0 in.)

Brake Type Hydraulic w/Brake Lever Lock and

Auxiliary Brake

Tire Size (Front)

(Rear)

AT21 x 7-10

AT2 0 x 11 - 9

AT22 x 7-10

AT2 2 x 10 - 1 0

Tire Inflation Pressure2(Front)

2(Rear)

0.28 kg/cm2 (4 psi)

0.25 kg/cm2 (3.5 psi)

MISCELLANY

Spark Plug Type NGK DPR7EA-9

Spark Plug Gap 0.8-0.9 mm (0.032-0.036 in.)

Gas Tank Capacity 12.8 L (3.4 U.S. gal.)

Reserve Capacity 4.54 L (1.2 U.S. gal.)

Engine Oil Capacity 1.6 L (1.7 U.S. qt) 1.4 L (1.5 U.S. gt)

Transmission (Overhaul)

Lubricant Capacity (Change)

400 ml (13.5 fl/oz)

300 ml (10.1 fl/oz)

600 ml (20.3 fl/oz)

500 ml (16.9 fl/oz)

Gasoline (recommended) 87 Octane Regular Unleaded

Engine Oil (recommended) Arctic Cat ACX All Weather (Synthetic)

Cooling System Capacity 1.4 L (1.5 U.S. qt)

Rear Drive Capacity N/A 150 ml (5 fl oz)

Rear Drive Lubricant N/A SAE Approved

80W-90 Hypoid

Brake Fluid DOT 4

Taillight/Brakelight 12V/5W/21W

Headlight 12V/35W (2)

Starting System Electric Electric w/Manual

Recoil (Emergency)

FUEL SYSTEM

Carburetor Type Keihin CVK32

Main Jet 112

Starter Jet 60

Slow Jet 38

Pilot Screw Setting (turns) 1 3/4

Needle Jet 4.0/3.6

Jet Needle NLRA

Idle RPM 1250-1350

Float Arm Height 17.0 mm (0.67 in.)

Throttle Cable Free-Play (at lever) 1-4 mm (1/16-3/16 in.)

IGNITION

Ignition Timing 5° BTDC (“F” mark) @1000

RPM

Spark Plug Cap 4500-6150 ohms

Ignition Coil Resistance (primary)

(secondary)

2.4-3.0 ohms (terminal to

terminal)

12,300-16,600 ohms (high

tension - plug cap removed -

to ground)

Ignition Coil Peak Voltage (primary/CDI) 9.6-16.4 DC volts

(black/white to green/gray)

MAGNETO

Magneto Coil Resistance (trigger)

(charging)

105-110 ohms

(blue/yellow to green/white)

Less than 1 ohm

(yellow to yellow)

Stator Coil Peak Voltage (trigger) 1.1-1.4 DC volts

(blue/yellow to green/white)

Magneto Output (approx) 220W @ 5000 RPM

Stator Coil Output (no load) 40-60 AC volts@3500 RPM

(yellow to yellow)

CAMSHAFT AND CYLINDER HEAD

Cam Lobe Height (min) (intake)

(exhaust)

34.15 mm

34.05 mm

Rocker Arm/Shaft Clearance (max) 0.1 mm

Cylinder Head/Cover Distortion (max) 0.05 mm

CYLINDER, PISTON, AND RINGS

Piston Skirt/Cylinder Clearance (max) 0.12 mm

Cylinder Bore 72.705-72.715 mm

Piston Diameter 18 mm from Skirt End

(max)

72.625 mm

Bore x Stroke 72.7 x 65.2 mm

Cylinder Trueness (max) 0.05 mm

Piston Ring to Groove Clearance (max)

(1st/2nd)

0.09 mm

Piston Ring End Gap - Installed (top)

(middle)

(oil)

0.15-0.30 mm

0.30-0.45 mm

0.20-0.70 mm

Piston Pin Bore (max) 17.06 mm

Piston Pin Outside Diameter (min) 16.96 mm

CRANKSHAFT

Connecting Rod (small end inside

diameter) (max)

17.06 mm

Connecting Rod (big end side-to-side) 0.05-0.40 mm

Connecting Rod (small end deflection)

(max)

1 mm

Crankshaft (web-to-web) 55.15-55.20 mm

Crankshaft Runout (max) 0.1 mm

Oil Pressure at 60°C (140°F) (above)

@ 3000 RPM (below)

0.3 kg/cm² (4.3 psi)

0.7 kg/cm² (10 psi)

TRANSMISSION

Clutch Release Screw 1/8 turn back

Drive Plate (fiber) Thickness (min) 2.4 mm

Drive Plate (fiber) Tab (min) 11 mm

Driven Plate (warpage) (max) 0.1 mm

Clutch Spring Length (min) 27.5 mm

Clutch Wheel Inside Diameter (max) Scuffing of contact surface

Clutch Shoe Lining Thickness 0.5 mm

Clutch Engagement RPM 2000 ± 200

Clutch Lock-Up RPM 3400 ± 300

VALVES AND GUIDES

Valve/Tappet Clearance (intake/exhaust)

(cold engine)

0.1 mm

Valve Guide/Stem Clearance (max)

(intake)

(exhaust)

0.06 mm

0.08 mm

Valve Spring Free Length (min) (inner)

(outer)

29.4 mm

39.0 mm

Valve Spring Tension @ 18.0 mm (intake) 10.2-11.8 kg (22.5-26.0 lb)

Valve Spring Tension @ 21.5 mm

(exhaust)

19.05-22.0 kg (42.0-48.5 lb)

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

Torque Specifications

*w/Red Loctite #271

STEERING COMPONENTS

Part Part Bolted To Torque

ft-lb N-m

Handlebar Clamp Cap Screw Steering Head 18 24

Steering Post Support Block Frame 17 23

Steering Post Nut Steering Post 50 68

Upper And Lower Ball Joint Nut Steering Knuckle 22 30

Tie Rod End Nut Steering Knuckle 15 20

Tie Rod Lock Nut Tie Rod 15 20

ELECTRICAL COMPONENTS

Starter Motor Lead Cable Nut Starter 36

in.-lb

Starter Motor Mounting Bolt Crankcase 9 12

EXHAUST COMPONENTS

Exhaust Pipe Engine 25 34

Muffler Mounting Bolt Frame 25 34

BRAKE COMPONENTS

Brake Hose Union Bolt Master Cylinder/

Caliper

25 34

Brake Bleed Screw Caliper 56

in.-lb

Brake Caliper Mounting Cap Screw Steering Knuckle/

Swing Arm

25 34

Master Cylinder (Front) Handlebar 13 18

Brake Pad Mounting Pin (Front/Rear) Brake Caliper 13 18

Brake Caliper Slide Pin (Front/Rear) Brake Caliper 25 34

Front Brake Line Nut Brake Line/Junction

Block

25 34

Brake Caliper (Rear) Swing Arm Housing 25 34

SUSPENSION COMPONENTS (Front)

A-Arm Pivot Nut Frame 32 44

Front Shock Absorber Mounting Nut*

(Upper/Lower)

Frame 29 39

SUSPENSION COMPONENTS (Rear)

Left Pivot Bolt (Utility) Swing Arm 36

in.-lb

Right Pivot Bolt (Utility) Swing Arm 82 112

Left Pivot Lock Nut (Utility) Left Pivot Bolt 82 112

Swing Arm Pivot Nut (DVX) Frame 50 68

Rear Shock Absorber Mounting Nut

(Upper/Lower)

Frame/Swing Arm 29 39

Axle Housing Cap Screw (Utility) Final Drive Gear

Case

40 54

Axle Housing Cap Screw (DVX) Swing Arm 29 39

DRIVE TRAIN COMPONENTS

Engine Mounting Through-Bolt Frame 29 39

Engine Mounting Bracket Cap Screw Frame 16 22

Rear Axle Housing (Utility) Swing Arm 40 54

Rear Axle Housing (DVX) Tube 29 39

Gear Case Swing Arm 50 68

Pinion Nut Shaft 72 98

Gear Case Cover (8 mm)

(10 mm)

Gear Case 19

Hub Nut (Front) Front/Spindle 50 68

Wheel Lug Nut Hub 32 44

Hub Nut (Rear) Axle 72 98

Rear Axle Nut* (Utility) Axle 72 98

Rear Axle Nut* (DVX) Axle 86 117

ENGINE/TRANSMISSION

Part Part Bolted To Torque

ft-lb N-m

Cylinder Head Cylinder 7 10

Cylinder Nut Crankcase 7 10

Camshaft Holder Cylinder Head 18 24

Bevel Drive Gear (Utility) Driveshaft 72 98

Magneto Rotor/Flywheel Crankshaft 47 64

Bevel Driven Gear (Utility) Driven Shaft 72 98

Output Drive Sprocket Lock Plate

(DVX)

Driveshaft 43 59

Crankcase Cap Screw Crankcase 8 11

Engine Oil Screen/Filter Cap Crankcase 11 15

Shift Cam Stopper Plug* (Utility) Left Case 20 27

Shift Cam Stopper Plug* (DVX) Transmission Case 35 48

Camshaft Chain Tensioner Adjuster Cam Chain

Tensioner

912

Cam Chain Tensioner Cover Bolt Tensioner 24

in.-lb

Starter Ratchet Crankshaft 68 92

Camshaft Chain Tensioner Mount Cylinder Head 9 12

Camshaft Chain Tension Spring Holder

Plug

Cam Chain

Tensioner

in.-lb

Centrifugal Clutch Housing Driveshaft 40 54

Timing Plug Right Case 16 22

Driven Pulley Retaining Nut Driven Shaft

(Transmission)

43 59

Drive Plate Nut* Fixed Driven Face 43 59

Drive Pulley Nut Crankshaft 72 98

Engine Oil Drain Plug Crankcase 21 29

Transmission Drain Plug Transmission 21 29

Transmission Case Cover Transmission 20 27

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

Torque Conversions

(ft-lb/N-m)

Break-In Procedure

A new ATV and an overhauled ATV engine require a

“break-in” period. The first 10 hours (or 200 miles) are

most critical to the life of this ATV. Proper operation dur-

ing this break-in period will help assure maximum life

and performance from the ATV.

During the first 10 hours (or 200 miles) of operation,

always use less than 1/2 throttle. Varying the engine

RPM during the break-in period allows the components

to “load” (aiding the mating process) and then “unload”

(allowing components to cool). Although it is essential to

place some stress on the engine components during

break-in, care should be taken not to overload the engine

too often. Do not pull a trailer or carry heavy loads dur-

ing the 10-hour break-in period.

When the engine starts, allow it to warm up properly. Idle

the engine several minutes until the engine has reached

normal operating temperature. Do not idle the engine for

excessively long periods of time.

During the break-in period, a maximum of 1/2 throttle is

recommended; however, brief full-throttle accelerations

and variations in driving speeds contribute to good

engine break-in.

After the completion of the break-in period, the engine

oil and oil filter should be changed. Other maintenance

after break-in should include checking of all prescribed

adjustments and tightening of all fasteners.

Gasoline - Oil - Lubricant

RECOMMENDED GASOLINE

The recommended gasoline to use is 87 minimum octane

regular unleaded. In many areas, oxygenates (either etha-

nol or MTBE) are added to the gasoline. Oxygenated

gasolines containing up to 10% ethanol, 5% methane, or

5% MTBE are acceptable gasolines.

When using ethanol blended gasoline, it is not necessary

to add a gasoline antifreeze since ethanol will prevent the

accumulation of moisture in the fuel system.

RECOMMENDED ENGINE OIL

The recommended oil to use is Arctic Cat ACX All

Weather synthetic engine oil, which has been specifically

formulated for use in this Arctic Cat engine. Although

Arctic Cat ACX All Weather synthetic engine oil is the

only oil recommended for use in this engine, use of any

API certified SM 0W-40 oil is acceptable.

OILCHARTJ

ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m

11.4 26 35.4 51 69.4 76 103.4

22.7 27 36.7 52 70.7 77 104.7

34.1 28 38.1 53 72.1 78 106.1

45.4 29 39.4 54 73.4 79 107.4

56.8 30 40.8 55 74.8 80 108.8

68.2 31 42.2 56 76.2 81 110.2

79.5 32 43.5 57 77.5 82 111.5

810.9 33 44.9 58 78.9 83 112.9

912.2 34 46.2 59 80.2 84 114.2

10 13.6 35 47.6 60 81.6 85 115.6

11 15 36 49 61 83 86 117

12 16.3 37 50.3 62 84.3 87 118.3

13 17.7 38 51.7 63 85.7 88 119.7

14 19 39 53 64 87 89 121

15 20.4 40 54.4 65 88.4 90 122.4

16 21.8 41 55.8 66 89.8 91 123.8

17 23.1 42 57.1 67 91.1 92 125.1

18 24.5 43 58.5 68 92.5 93 126.5

19 25.8 44 59.8 69 93.8 94 127.8

20 27.2 45 61.2 70 95.2 95 129.2

21 28.6 46 62.6 71 96.6 96 130.6

22 29.9 47 63.9 72 97.9 97 131.9

23 31.3 48 65.3 73 99.3 98 133.3

24 32.6 49 66.6 74 100.6 99 134.6

25 34 50 68 75 102 100 136

CAUTION

Do not use white gas. Only Arctic Cat approved gaso-

line additives should be used.

CAUTION

Any oil used in place of the recommended oil could

cause serious engine damage. Do not use oils which

contain graphite or molybdenum additives. These oils

can adversely affect clutch operation. Also, not recom-

mended are racing, vegetable, non-detergent, and cas-

tor-based oils.

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

RECOMMENDED REAR DRIVE

LUBRICANT (Utility)

The recommended lubricant is Arctic Cat Gear Lube or

an equivalent gear lube which is SAE approved 80W-90

hypoid. This lubricant meets all of the lubrication

requirements of the Arctic Cat ATV rear drive.

RECOMMENDED TRANSMISSION

LUBRICANT

The recommended lubricant is Arctic Cat Gear Lube or an

equivalent gear lube which is SAE approved 80W-90

hypoid. This lubricant meets all the lubrication requirements

of the Arctic Cat ATV front differential and rear drive.

FILLING GAS TANK

Since gasoline expands as its temperature rises, the gas

tank must be filled to its rated capacity only. Expansion

room must be maintained in the tank particularly if the

tank is filled with cold gasoline and then moved to a

warm area.

ATV0049B

Tighten the gas tank cap securely after filling the tank.

Genuine Parts

When replacement of parts is necessary, use only genuine

Arctic Cat ATV parts. They are precision-made to ensure

high quality and correct fit. Refer to the appropriate Illus-

trated Parts Manual for the correct part number, quantity,

and description.

Preparation For Storage

Arctic Cat recommends the following procedure to pre-

pare the ATV for storage.

1. Clean the seat cushion (cover and base) with a damp

cloth and allow it to dry.

2. Clean the ATV thoroughly by washing dirt, oil,

grass, and other foreign matter from the entire ATV.

Allow the ATV to dry thoroughly. DO NOT get

water into any part of the engine or air intake.

3. Either drain the gas tank or add Fuel Stabilizer to the

gas in the gas tank. Remove the air filter housing

cover and air filter. Start the engine and allow it to

idle; then using Arctic Cat Engine Storage Preserver,

slowly inject the preserver into the air filter opening

for a period of 10 to 20 seconds; then stop the

engine. Install the air filter and housing cover.

4. Drain the carburetor float chamber.

5. Plug the exhaust hole in the exhaust system with a

clean cloth.

6. Apply light oil to the upper steering post bushing and

plungers of the shock absorbers.

7. Tighten all nuts, bolts, cap screws, and screws. Make

sure rivets holding components together are tight.

Replace all loose rivets. Care must be taken that all

calibrated nuts, cap screws, and bolts are tightened to

specifications.

8. Fill the cooling system to the FULL line in the cool-

ing system reservoir with properly mixed coolant.

CAUTION

Any lubricant used in place of the recommended lubri-

cant could cause serious rear drive damage.

CAUTION

Any lubricant used in place of the recommended lubri-

cant could cause serious front differential/rear drive

damage.

! WARNING

Always fill the gas tank in a well-ventilated area. Never

add fuel to the ATV gas tank near any open flames or

with the engine running. DO NOT SMOKE while filling

the gas tank.

! WARNING

Do not overflow gasoline when filling the gas tank. A

fire hazard could materialize. Always allow the engine to

cool before filling the gas tank.

! WARNING

Do not over-fill the gas tank.

CAUTION

Prior to storing the ATV, it must be properly serviced to

prevent rusting and component deterioration.

CAUTION

Rapid induction of oil or any liquid into a four-cycle

engine can cause “hydraulic-lock” resulting in severe

engine damage.

CAUTION

If the interior of the air filter housing is dirty, clean the

area before starting the engine.

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

9. Disconnect the battery cables; then remove the bat-

tery, clean the battery posts and cables, and store in a

clean, dry area.

10. Store the ATV indoors in a level position.

Preparation After

Storage

Taking the ATV out of storage and correctly preparing it

will assure many miles and hours of trouble-free riding.

Arctic Cat recommends the following procedure to pre-

pare the ATV.

1. Clean the ATV thoroughly.

2. Clean the engine. Remove the cloth from the exhaust

system.

3. Check all control wires and cables for signs of wear

or fraying. Replace if necessary.

4. Change the engine oil and filter.

5. Check the coolant level and add properly mixed

coolant as necessary.

6. Charge the battery; then install. Connect the battery

cables.

7. Check the entire brake systems (fluid level, pads,

etc.), all controls, headlights, taillight, brakelight,

and headlight aim; adjust or replace as necessary.

8. Tighten all nuts, bolts, cap screws, and screws mak-

ing sure all calibrated nuts, cap screws, and bolts are

tightened to specifications.

9. Check tire pressure. Inflate to recommended pressure

as necessary.

10. Make sure the steering moves freely and does not

bind.

11. Check the spark plug. Clean or replace as necessary.

CAUTION

This maintenance-free battery should be charged at the

recommended rate every 30 days or permanent damage

may occur if the battery completely discharges.

CAUTION

Avoid storing outside in direct sunlight and avoid using

a plastic cover as moisture will collect on the ATV caus-

ing rusting.

CAUTION

The ignition switch must be in the OFF position prior to

installing the battery or damage may occur to the igni-

tion system.

CAUTION

Connect the positive battery cable first; then the nega-

tive.

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

Periodic Maintenance/

Tune-Up

SPECIAL TOOLS

A number of special tools must be available to the techni-

cian when performing service procedures in this section.

Refer to the current Special Tools Catalog for the appro-

priate tool description.

NOTE: Special tools are available from the Arctic

Cat Service Parts Department.

Periodic Maintenance

Chart

A = Adjust I = Inspect C = Clean L = Lubricate D = Drain R = Replace T = Tighten

* Service/Inspect more frequently when operating in adverse conditions.

** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year.

Description p/n

Compression Tester Kit 0444-213

Tappet Adjuster 0444-189

Item

Initial Service After

Break-In (First

Month or 100 Miles)

Every

Day

Every Month or

Every 100 Miles

Every 3 Months

or Every 300

Miles

Every 6 Months

or Every 500

Miles

Every Year

or Every

1500 Miles

Needed

Battery I I C

Air Filter/Drain Tube I I C* R

Valve/Tappet Clearance I I A

Spark Plug I I R (4000 Mi

or 18 Mo)

Muffler/Spark Arrester CR

Gas/Vent Hoses I I R (2 Yrs)

Gas Tank Valve IC

Throttle Cable I I C-L A-R

Carb Float Chamber D*

Engine RPM (Idle) I I A

Engine Oil Level I A

Engine Oil - Screen* C C** C

Drive Chain (DVX) I I C-L

Rear Drive Lubricant (Utility) I I R A

Transmission Lubricant I I R A

Tires/Air Pressure I I A-R

Steering Components I I I R

V-Belt I IR

Suspension (Ball joint boots, tie

rods, differential and rear drive

bellows)

II l* R

Nuts/Cap Screws/Screws I I T

Ignition Timing I

Headlight/Taillight-Brakelight I I R

Switches I I R

Shift Lever IA-L

Choke Cable I C-L R

Recoil Starter (Utility) I C-R

Handlebar Grips I R

Handlebars I I R

Gauges/Indicators I I R

Frame/Welds/Racks I I l

Electrical Connections lC

Complete Brake System (Hydraulic

and Auxiliary)

II C L-R

Brake Pads I I* R

Brake Fluid I I R (2 Yrs)

Brake Hoses I I R (4 Yrs)

Coolant/Cooling System I I R (2 Yrs)

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

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Lubrication Points

It is advisable to lubricate certain components periodi-

cally to ensure free movement. Apply light oil to the

components using the following list as reference.

A. Throttle Lever Pivot/Cable Ends

B. Brake Lever Pivot

C. Auxiliary Brake Pivot/Clevis

D. Choke Cable Upper End

E. Shift Lever/Ball Joints

F. Idle RPM Screw

Air Filter

Use the following procedure to remove the filter and

inspect and/or clean it.

CLEANING AND INSPECTING

FILTER

1. Remove the seat.

2. Remove the air filter housing cover from the retain-

ing clips.

KM095A

3. Loosen the clamp; then remove the filter.

KM097B

4. Fill a wash pan larger than the filter with a non-flam-

mable cleaning solvent; then dip the filter in the sol-

vent and wash it.

NOTE: Foam Filter Cleaner and Foam Filter Oil are

available from Arctic Cat.

5. Dry the filter.

6. Put the filter in a plastic bag; then pour in air filter oil

and work the filter.

7. Clean any dirt or debris from inside the air cleaner.

Make sure no dirt enters the carburetor.

8. Place the filter in the air filter housing making sure it

is properly seated and secure with the clamp.

9. Install the air filter housing cover and secure with the

retaining clips; then install the seat making sure it

locks securely.

CHECKING/DRAINING DRAIN TUBE

Periodically check the drain tube for gasoline or oil accu-

mulation. If noticed, remove the drain tube cap from

beneath the housing and drain the gasoline or oil into a

suitable container; then install and secure the tube cap.

KM114

Valve/Tappet Clearance

To check and adjust valve/tappet clearance, use the fol-

lowing procedure.

NOTE: The seat assembly, side panels, and gas

tank must be removed for this procedure.

1. Remove the timing inspection plug; then remove the

cylinder head cover (see Engine/Transmission -

Removing Top-Side Components).

2. Rotate the crankshaft so the “T” mark on the fly-

wheel aligns with the index mark on the right-side

crankcase cover.

NOTE: At this point, the round hole in the camshaft

gear should be up.

CAUTION

Failure to inspect the air filter frequently if the vehicle is used

in dusty, wet, or muddy conditions can damage the engine.

CAUTION

A torn air filter can cause damage to the ATV engine. Dirt

and dust may get inside the engine if the element is torn.

Carefully examine the element for tears before and after

cleaning it. Replace the element with a new one if it is torn.

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3. Place Tappet Adjuster onto the jam nut securing the

tappet adjuster screw; then rotate the adjuster dial

clockwise until the end is seated in the tappet

adjuster screw.

4. While holding the adjuster dial in place, use the

adjuster handle and loosen the jam nut; then rotate the

tappet adjuster screw clockwise until friction is felt.

5. Align the adjuster handle with one of the marks on

the adjuster dial.

6. While holding the adjuster handle in place, rotate the

adjuster dial counterclockwise until proper valve/

tappet clearance is attained.



NOTE: Refer to the appropriate specifications in Engine/

Transmission for the proper valve/tappet clearance.

NOTE: Rotating the adjuster dial counterclockwise

will open the valve/tappet clearance by 0.05 mm

(0.002 in.) per mark.

7. While holding the adjuster dial at the proper clear-

ance setting, tighten the jam nut securely with the

valve adjuster handle.

8. Place the cylinder head cover with a new O-ring into

position; then tighten the cover securely.

KM703

9. Install the timing inspection plug.

Testing Engine

Compression

To test engine compression, use the following procedure.

1. Remove the high tension lead from the spark plug.

2. Using compressed air, blow any debris from around

the spark plug.

3. Remove the spark plug; then attach the high tension

lead to the plug and ground the plug on the cylinder

head well away from the spark plug hole.

4. Attach the gauge from Compression Tester Kit.

NOTE: The engine must be warm and the battery

must be fully charged for this test.

5. While holding the throttle lever in the full-open posi-

tion, crank the engine over with the electric starter

until the gauge shows a peak reading (five to 10

compression strokes).

NOTE: The compression should be within a range

of 210-230 psi in the full-open throttle position.

6. If compression is abnormally low, verify the follow-

ing items.

A. Starter cranks engine over.

B. Gauge functions properly.

C. Throttle lever in the full-open position.

D. Valve/tappet clearance correct.

E. Valve not bent or discolored.

F. Valve seat not discolored.

NOTE: To service valves, see Engine/Transmission.

7. Pour 29.5 ml (1 fl oz) of oil into the spark plug hole,

attach the gauge, and test compression.

8. If compression is now evident, service the piston

rings (see Engine/Transmission).

Spark Plug

A light brown insulator indicates that the plug is correct.

A white or dark insulator indicates that the engine may

need to be serviced or the carburetor may need to be

adjusted. To maintain a hot, strong spark, keep the plug

free of carbon.

ATV-0051

Adjust the gap to 0.8-0.9 mm (0.032-0.036 in.) for proper

ignition. Use a wire feeler gauge to check the gap.

! WARNING

Always wear safety glasses when using compressed air.

CAUTION

Before removing the spark plug, make sure to clean the

area around the spark plug. Dirt could enter engine

when removing or installing the spark plug.

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ATV0052B

When installing the spark plug, make sure to tighten it

securely. A new spark plug should be tightened 1/2 turn

once the washer contacts the cylinder head. A used spark

plug should be tightened 1/8-1/4 turn once the washer

contacts the cylinder head.

Muffler/Spark Arrester

The muffler has a spark arrester which must be periodi-

cally cleaned. At the intervals shown in the Periodic

Maintenance Chart, clean the spark arrester using the fol-

lowing procedure.

1. Remove the cap screw (1) securing the spark arrester

(2) to the muffler assembly; then carefully remove

the spark arrester.

KM139A

2. Using a soft wire brush, clean the carbon from the

screen (3) taking care not to tear or damage the screen.

KM140B

3. Install the spark arrester and secure with the cap

screw. Tighten securely.

Engine Oil - Filter

Replace the engine oil and clean the screen/filter at the

scheduled intervals. The engine should always be warm

when the oil is changed so the oil will drain easily and

completely.

1. Park the ATV on level ground.

2. Loosen the oil fill plug.

KM126A

3. Remove the screen/filter cap from the bottom of the

engine and drain the oil into a drain pan. Account for

a spring, O-ring, and screen/filter.

DSC02248

4. Clean the screen/filter in parts-cleaning solvent; then

inspect the O-ring and replace if damaged.

! WARNING

Wait until the muffler cools to avoid burns.

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5. Install the screen/filter, spring, and screen/filter cap

into the bottom of the engine and tighten to 11 ft-lb.

6. Remove the oil fill plug and pour in 1.6 L (1.7 U.S.

qt) of the recommended oil into the fill hole; then

install the oil fill plug.

7. Start the engine (while the ATV is outside on level

ground) and allow it to idle for a few minutes.

8. Turn the engine off and wait approximately one minute.

Check the oil level in the engine oil inspection window.

The oil level should be visible through the window. If

oil is not visible, add recommended oil until the oil

level is visible between the lines of the window.

KM127A

9. Inspect the area around the screen/filter cap for leaks.

Rear Drive Lubricant

(Utility)

Check and change the lubricant according to the Periodic

Maintenance Chart. When changing the lubricant, use

approved SAE 80W-90 hypoid gear lube. To check lubri-

cant, use the following procedure.

1. Remove the rear drive level plug; the lubricant level

should be at the threads of the plug.

KM131A

2. If low, add SAE approved 80W-90 hypoid gear lube

as necessary.

To change the lubricant, use the following procedure.

1. Place the ATV on level ground.

2. Loosen the fill plug.

3. Remove the cap screws securing the rear drive gear

guard; then remove the guard.

4. Drain the lubricant into a drain pan by removing the

drain plug from the bottom of the rear drive.

NOTE: If the rear drive lubricant is contaminated

with water, inspect the drain plug, fill plug, and/or

bladder.

5. After all the lubricant has been drained, install the

drain plug and tighten securely. Install the rear drive

gear guard and tighten the cap screws securely.

6. Pour the appropriate amount of recommended lubri-

cant into the fill hole. Remove the level plug and

check for appropriate level.

7. Install the fill plug.

Transmission Lubricant

Change the lubricant according to the Periodic Mainte-

nance Chart. When changing the lubricant, use approved

SAE 80W-90 hypoid gear lube.

To change the lubricant, use the following procedure.

1. Place the ATV on level ground.

2. Loosen the fill plug; then remove the transmission

drain plug and drain the transmission lubricant.

KM104A

CAUTION

Any oil used in place of the recommended oil could

cause serious engine damage. Do not use oils which

contain graphite or molybdenum additives. These oils

can adversely affect clutch operation. Also, not recom-

mended are racing, vegetable, non-detergent, and cas-

tor-based oils.

CAUTION

Water entering the outer end of the axle will not be able

to enter the rear drive unless the seals are damaged.

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KM106A

3. Install the drain plug and tighten securely.

4. Remove the fill plug and pour the appropriate

amount of recommended lubricant into the fill hole.

5. Install the fill plug and tighten securely.

6. Check the area around the drain plug for leakage.

Drive Chain (DVX)

Drive chain condition and adjustment should be

inspected each day before the ATV is operated. Always

follow the following guidelines for inspecting and servic-

ing the drive chain.

INSPECTING

Inspect the drive chain for any of the following conditions.

A. Loose pins.

B. Loose or cracked rollers.

C. Dry or rusted links.

D. Kinked or binding links.

E. Excessive wear.

The presence of any of the conditions requires drive

chain replacement.

NOTE: If the drive chain is worn or damaged, the

sprockets may also be worn or damaged. Inspect the

sprockets for worn, broken, or damaged teeth.

Always inspect the sprockets when a new drive chain

is being installed.

CLEANING AND LUBRICATING

The drive chain should be cleaned and lubricated fre-

quently to prolong chain and sprocket life. Use the fol-

lowing procedure to clean and lubricate the chain.

NOTE: This ATV is equipped with an O-ring type

roller chain. Each link incorporates small O-rings to

seal out water and dirt. Care should be taken to

choose cleaning solutions and lubricants that are

suitable for O-ring type chains.

1. Using a suitable, nonflammable cleaning solution,

thoroughly wash the chain and sprockets.

2. Allow the chain to dry; then apply a dry, graphite-

based lubricant to the chain.

NOTE: The drive chain should be lubricated with a

dry, graphite-based chain lubricant. By using a dry,

graphite-based chain lubricant, dirt build-up on the

drive chain will be minimized.

ADJUSTING TENSION

1. Loosen the four cap screws (1) at the rear of the axle

housing; then loosen the cap screw (2) on the front of

the brake caliper.

KM902A

2. Install an appropriate pin through the axle hub and

rear sprocket.

KM158A

3. With a person seated on the ATV, check chain ten-

sion at the mid-point of the chain.

NOTE: Chain “slack” should be within a range of

30-40 mm (1.2-1.6 in.).

4. Push the ATV forward to tighten chain tension; push

the ATV backward to loosen chain tension.

5. Tighten the four cap screws (1) to 29 ft-lb; then

tighten the cap screw (2) to 29 ft-lb.

! WARNING

Failure to inspect and maintain the drive chain can be

hazardous. Operating the ATV with the drive chain in

poor condition or improperly adjusted can cause an

accident resulting in possible injury.

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KM902A

Driveshaft/Coupling

(Utility)

The following drive system components should be

inspected periodically to ensure proper operation.

A. Spline lateral movement (slop).

B. Coupling not cracked, damaged, or worn.

Nuts/Bolts/Cap Screws

Tighten all nuts, bolts, and cap screws. Make sure rivets

holding components together are tight. Replace all loose

rivets. Care must be taken that all calibrated nuts, bolts,

and cap screws are tightened to specifications.

Headlight/Taillight-

Brakelight

Each time the ATV is used, lights should be checked for

proper function. Turn the ignition switch to the LIGHTS

position; the headlights and taillight should illuminate.

Test the brakelight by compressing the brake lever. The

brakelight should illuminate.

NOTE: The bulb portion of the headlight is fragile.

HANDLE WITH CARE. When replacing the headlight

bulb, do not touch the glass portion of the bulb. If the

glass is touched, it must be cleaned with a dry cloth

before installing. Skin oil residue on the bulb will

shorten the life of the bulb.

To replace the headlight bulb, use the following procedure.

1. Remove the boot from the back of the headlight

housing; then remove the three-wire connector from

the bulb.

2. Using care not to bend or deform the spring clip,

release the two ends of the spring clip from the light

housing; then remove the bulb from the headlight

housing.

KM192A

3. Install the new bulb into the headlight housing; then

secure with the spring clip.

4. Connect the three-wire connector to the bulb; then

install the boot.

To replace the taillight-brakelight bulb, use the following

procedure.

1. Remove the two screws and remove the lens cover.

2. Push the bulb in and turn it counterclockwise.

3. Install the new bulb by turning it clockwise while

pushing in.

4. Install the lens cover.

Shift Lever

KM363A

! WARNING

Do not attempt to remove the bulb when it is hot. Severe

burns may result.

CAUTION

Tighten the lens cover screws only until they are snug.

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KM124B

CHECKING ADJUSTMENT

Stop the ATV completely and shift the transmission into

the R position. The reverse gear indicator light should be

illuminated.

If the reverse gear indicator light does not illuminate

when shifted to the reverse position, the switch may be

faulty, the fuse may be blown, the bulb may be faulty, a

connection may be loose or corroded, or the lever may

need adjusting. To adjust, proceed to Adjusting Shift

Lever.

ADJUSTING SHIFT LEVER

1. Place the shift lever in the N (neutral) position; then

set the engine stop switch to the STOP position and

turn the ignition switch to the RUN position. The

neutral indicator light should illuminate.

NOTE: If the neutral indicator light does not illumi-

nate, adjustment of the shift linkage will be required.

To adjust, proceed to step 2.

2. Loosen the jam nuts on both ends of the shift rod and

turn the shift rod until the neutral light illuminates.

Tighten the jam nuts securely.

KM313

NOTE: On the DVX, the neutral position in the trans-

mission is indexed by passing a Phillips screwdriver

through the transmission shift arm and into the index

hole in the transmission cover.

KM179A

Hydraulic Brake Systems

CHECKING/BLEEDING

The hydraulic brake systems have been filled and bled at

the factory. To check and/or bleed a hydraulic brake sys-

tem, use the following procedure.

1. With the master cylinder in a level position, check

the fluid level in the reservoir. If the level in the res-

ervoir is not visible in the sight glass, add DOT 4

brake fluid.

KM113

KM137

2. Compress the brake lever/pedal several times to

check for a firm brake. If the brake is not firm, the

system must be bled.

3. To bleed the brake system, use the following proce-

dure.

! WARNING

Never shift the ATV into reverse gear when the ATV is

moving as it could cause the ATV to stop suddenly

throwing the operator from the ATV.

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A. Remove the cover and fill the reservoir with DOT

4 Brake Fluid.

B. Install and secure the cover; then slowly compress

the brake lever several times.

C. Remove the protective cap, install one end of a

clear hose onto one FRONT bleed screw, and

direct the other end into a container; then while

holding slight pressure on the brake lever, open

the bleed screw and watch for air bubbles. Close

the bleed screw before releasing the brake lever.

Repeat this procedure until no air bubbles are

present.

KM116A

NOTE: During the bleeding procedure, watch the

reservoir sight glass very closely to make sure there

is always a sufficient amount of brake fluid. Failure to

maintain a sufficient amount of fluid in the reservoir

will result in air in the system.

D. At this point, perform steps B and C on the other

FRONT bleed screw; then move to the REAR

bleed screw and follow the same procedure.

4. Carefully check the entire hydraulic brake system

that all hose connections are tight, the bleed screws

are tight, the protective caps are installed, and no

leakage is present.

INSPECTING HOSES

Carefully inspect the hydraulic brake hoses for cracks or

other damage. If found, the brake hoses must be replaced.

CHECKING/REPLACING FRONT

PADS

The clearance between the brake pads and brake discs is

adjusted automatically as the brake pads wear. The only

maintenance that is required is replacement of the brake

pads when they show excessive wear. Check the thick-

ness of each of the brake pads as follows.

1. Remove a front wheel.

2. Measure the thickness of each brake pad.

3. If thickness of either brake pad is less than 1.0 mm

(0.039 in.), the brake pad must be replaced.

NOTE: The brake pads should be replaced as a set.

4. To replace the brake pads, use the following proce-

dure.

A. With the wheel removed, remove the brake pad

alignment pins from the caliper; then remove the

mounting cap screws.

KM265A

KM266A

B. Remove the caliper from the disc; then compress

the caliper holder and remove the brake pads.

KM267

C. Install new brake pads; then install the two brake

pad alignment pins.

CAUTION

This hydraulic brake system is designed to use DOT 4

brake fluid only. If brake fluid must be added, care must

be taken as brake fluid is very corrosive to painted sur-

faces.

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KM268

D. Spread the brake pads and place the brake caliper

over the disc. Secure with the mounting cap

screws. Tighten the cap screws to 25 ft-lb; then

tighten the alignment pins to 13 ft-lb.

KM266A

5. Install the wheel. Tighten to 32 ft-lb.

6. Burnish the brake pads (see Burnishing Brake Pads

in this section).

Auxiliary/Rear Hydraulic

Brake

CHECKING

1. With the engine off, the transmission in neutral, and

the reverse lever in the forward position, press the

brake pedal and attempt to move the ATV.

2. If the rear wheels are locked, it is functioning prop-

erly.

3. If the rear wheels are not locked, it must be repaired

or bled.

BLEEDING

To bleed the auxiliary brake, see Hydraulic Brake Sys-

tems - CHECKING/BLEEDING in this section.

MEASURING/REPLACING REAR

BRAKE PADS (Utility)

Removing

1. Support the ATV on a suitable support stand.

2. Remove the left rear wheel.

3. Remove the two brake pad alignment pins (A); then

remove the mounting cap screws (B).

KM273A

4. Remove the caliper from the disc; then compress the

caliper holder and remove the brake pads.

KM267

Inspecting and Measuring

1. Inspect the pads for gouges, chips, or wear.

2. Inspect the disc for gouges, grooves, cracks, and

warpage.

3. Using a calipers, measure the thickness of each brake

pad.

4. If the thickness of either brake pad is less than 1.0

mm (0.039 in.), the brake pad must be replaced.

NOTE: The brake pads should be replaced as a set.

Installing

1. Install new brake pads; then install the two brake pad

alignment pins.

2. Spread the brake pads and place the brake caliper

over the disc; then secure with the mounting cap

screws (B). Tighten the cap screws to 25 ft-lb; then

tighten the alignment pins (A) to 13 ft-lb.

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KM273A

3. Install the wheel and secure. Tighten to 32 ft-lb.

4. Remove the ATV from the support stand.

NOTE: Whenever installing new pads, the new pads

must be burnished (see Burnishing Brake Pads in

this section).

MEASURING/REPLACING REAR/

AUXILIARY BRAKE PADS (DVX)

Removing

NOTE: The brake caliper on the DVX contains two

sets of brake pads. The front pads are controlled by

the main brake lever and the rear pads are controlled

by the auxiliary brake pedal.

1. Remove the brake pad dust cover; then remove the

clip pin and pull the brake pad retaining pin out of

the caliper.

KM902B

KM244

2. Remove the brake spring plate; then remove the

brake pads.

KM905

Inspecting and Measuring

1. Inspect the pads for gouges, chips, or wear.

2. Inspect the disc for gouges, grooves, cracks, and

warpage.

3. Using a calipers, measure the thickness of each brake pad.

4. If the thickness of any brake pad is less than 1.0 mm

(0.039 in.), the brake pad must be replaced.

NOTE: The brake pads should be replaced as a set.

5. Using a calipers, measure the thickness of the disc. If

any portion of the disc is less than 3.00 mm (0.12

in.), the disc must be replaced (see Drive System).

Installing

1. Install the brake pads in the caliper; then insert the

brake spring plate.

KM245

2. Install the brake pad retaining pin and secure with

the clip pin; then install the dust cover.

KM244

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3. Burnish the brake pads (see Burnishing Brake Pads

in this section).

Burnishing Brake Pads

Brake pads (both hydraulic and auxiliary) must be bur-

nished to achieve full braking effectiveness. Braking dis-

tance will be extended until brake pads are properly

burnished. To properly burnish the brake pads, use the

following procedure.

1. Choose an area large enough to safely accelerate the

ATV to 30 mph and to brake to a stop.

2. Accelerate to 30 mph; then compress brake lever or

apply the auxiliary brake to decelerate to 0-5 mph.

3. Repeat procedure on each brake system five times

until brake pads are burnished.

4. Adjust the auxiliary brake (if necessary).

5. Verify that the brakelight illuminates when the hand

lever is compressed or the brake pedal is depressed.

Checking/Replacing

V-Belt

REMOVING

1. On the Utility, remove the left footwell; then remove

the recoil starter assembly. On the DVX, proceed to

step 2.

KM279

2. Remove the front and rear V-belt housing cooling

ducts.

3. Remove the cap screws securing the V-belt cover

noting the location of the different-lengthed cap

screws for installing purposes; then using a rubber

mallet, gently tap on the cover tabs to loosen the

cover. Remove the cover. Account for two alignment

pins and one gasket.

KM253

4. Remove the nut securing the movable drive face;

then remove the face. Account for the stepped

washer and spacer.

KM276

5. Remove the nut securing the driven pulley; then

remove the splined bushing, centrifugal clutch, pul-

ley, and V-belt.

INSTALLING

1. Using a rubber mallet, spread the driven pulley

sheaves by driving the V-belt down between the

sheaves; then slide the driven pulley and V-belt into

position.

KM262

2. Install the centrifugal clutch housing onto the driven

shaft; then install the splined bushing and secure

with the driven pulley retaining nut. Tighten to 40 ft-

lb.

! WARNING

Failure to properly burnish the brake pads could lead to

premature brake pad wear or brake loss. Brake loss can

result in severe injury.

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KM276

3. Install the movable drive face onto the crankshaft

making sure to “bottom” the sheave out against the

center bushing. The crankshaft splines should be vis-

ible and the stepped washer should sit over the

splines.

KM263A

4. Secure the movable drive face to the crankshaft with

the drive pulley nut and tighten to 72 ft-lb.

5. Install the V-belt cover and tighten the cap screws

securely; then connect the cooling boots and tighten

the clamps securely.

KM252A

6. Install the recoil starter and footwell assembly (Util-

ity). Tighten all hardware securely.

CAUTION

If the splines are not protruding as shown, the V-belt

may be too deep in the drive sheaves. This would cause

the drive pulley to be under-tightened and severe drive

sheave or crankshaft damage could occur.

CAUTION

On the DVX, the rear boot clamp must be oriented as

shown or interference with heat shielding could occur.

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Engine/Transmission

This section has been organized into sub-sections which

show a progression for the complete servicing of the Arc-

tic Cat ATV engine/transmission.

To service the center crankcase halves, the engine/trans-

mission must be removed from the frame.

To service top-side, left-side, and right-side components,

the engine/transmission does not have to be removed

from the frame.



NOTE: Arctic Cat recommends the use of new gas-

kets, lock nuts, and seals and lubricating all internal

components when servicing the engine/transmission.

SPECIAL TOOLS

A number of special tools must be available to the techni-

cian when performing service procedures in this section.

Refer to the current Special Tools Catalog for the appro-

priate tool description.

NOTE: Special tools are available from the Arctic

Cat Service Parts Department.

Description p/n

Crankcase Separator/Crankshaft Remover 0444-152

Piston Pin Puller 0644-328

Spanner Wrench 0444-192

Flywheel Holder 0444-193

Magneto Rotor Remover 0444-187

Tappet Adjuster 0444-189

Surface Plate 0644-016

Driven Pulley Compressor 0444-195

V Blocks 0644-535

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Removing Engine/

Transmission

Many service procedures can be performed without

removing the engine/transmission from the frame.

Closely observe the note introducing each sub-section for

this important information.

Secure the ATV on a support stand to elevate the wheels.

DVX

1. Remove the seat.

2. Remove the negative cable from the battery; then

remove the positive cable. Remove the battery hold-

down strap; then remove the battery.

3. Remove the reinstallable rivet from the bottom of the

electrical tray; then remove and lay the tray forward.

Leave the starter relay, fuse block, and CDI attached.

KM357

4. Remove the gas tank cover panel; then install the gas

tank cap and remove the gas tank vent hose.

5. Remove the body (see Steering/Frame).

6. Remove the air filter housing (see Fuel/Lubrication/

Cooling).

7. Remove the gas tank (see Fuel/Lubrication/Cooling).

8. Remove the muffler assembly (see Steering/Frame).

9. Remove the carburetor (see Fuel/Lubrication/Cooling).

10. Remove the coil (see Electrical System).

11. Disconnect the stator connector, shift position con-

nector, and coolant temperature sensor.

KM348A

KM324A

12. Remove the starter positive wire; then remove the

engine ground wire.

KM319A

13. Drain the coolant, engine oil, and transmission gear lubri-

cant; then install the drain plugs and tighten to 21 ft-lb.

KM314A

AT THIS POINT

If the technician’s objective is to service/replace left-

side cover oil seals, the engine/transmission does not

have to be removed from the frame.

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

! WARNING

Battery acid is harmful if it contacts eyes, skin, or cloth-

ing. Care must be taken whenever handling a battery.

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KM147A

KM106A

14. Loosen the clamps; then remove the front and rear V-

belt cooling boots from the V-belt housing.

KM359A

KM360A

15. Loosen the clamps; then disconnect the coolant

hoses from the engine.

KM323

KM314

16. Remove the output drive sprocket cover; then

remove the output drive sprocket.

KM344A

17. Disconnect the shift linkage from the transmission

shift arm.

KM313

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18. Remove the front engine mounting through-bolt;

then remove the left and right engine mounting

brackets from the frame.

19. Attach a suitable lifting sling and engine lift to the

front engine mounting boss.

KM332

20. Raise the engine lift to take the slack out of the sling;

then remove the upper rear and lower rear engine

through-bolts.

KM333A

KM325A

21. Raise the front of the engine sufficiently to allow the

engine assembly to be moved forward enough to clear

the rear mounting brackets (approximately 6 in.).

22. Lower the front of the engine slowly, swing the rear

of the engine to the left, and slide the engine out of

the left-side of the frame.

KM330

KM331

Utility

1. Remove the seat; then remove the battery box cover.

KM133A

2. Remove the negative cable from the battery; then

remove the positive cable.

3. Drain the coolant, engine oil, and transmission gear

lubricant; then install the drain plugs and tighten to

21 ft-lb.

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KM314A

KM314B

KM106A

4. Remove the gas tank cover panel and gas tank vent

hose.

5. Remove the side panels; then remove the front rack

and front fenders (see Steering/Frame).

6. Remove the air filter housing (see Fuel/Lubrication/

Cooling.

7. Remove the gas tank (see Fuel/Lubrication/Cooling).

8. Remove the muffler assembly (see Steering/Frame).

9. Remove the carburetor (see Fuel/Lubrication/Cool-

ing).

10. Remove the coil (see Electrical System).

11. Disconnect the stator connector, shift position con-

nector, trigger coil connector, and coolant tempera-

ture sensor.

KM347A

KM324A

12. Remove the starter positive wire; then remove the

engine ground wire from the crankcase.

KM319A

13. Remove the front and rear V-belt cooling boots from

the V-belt housing; then remove the coolant hoses

from the engine.

KM359A

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KM360A

KM323

KM314

14. Loosen the output drive boot clamp; then slide the

boot off the output housing.

KM315A

15. Disconnect the shift linkage from the transmission

shift arm; then swing the shift linkage forward and

out of the way.

16. Remove the front engine through-bolt; then remove

the two engine mounting brackets from the frame.

KM414A

17. Attach a suitable lifting sling and engine lift to the

front engine mounting boss; then using an engine

lift, apply slight upward pressure on the engine/

transmission.

KM332A

18. Remove the upper rear and lower rear engine

through-bolts to free the engine/transmission; then

raise the front of the engine/transmission sufficiently

to allow the engine assembly to be moved forward

enough to disengage the driveshaft.

KM333A

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KM325A

19. Swing the rear of the engine/transmission to the left;

then slide the engine out of the left-side of the frame.

KM329

KM331

Top-Side Components

NOTE: For efficiency, it is preferable to remove and

disassemble only those components which need to

be addressed and to service only those components.

The technician should use discretion and sound

judgment.

NOTE: The engine/transmission does not have to

removed from the frame for this procedure.

Removing Top-Side

Components

A. Valve Cover

B. Cylinder Head

NOTE: Remove the spark plug and timing inspec-

tion plug; then rotate the crankshaft to top-dead-cen-

ter of the compression stroke.

1. Remove the cap screws securing the cylinder head

cover. Account for the O-ring.

KM703

NOTE: Keep the mounting hardware with the cover

for assembly purposes.

2. Remove the plug from the cam chain tensioner; then

turn the cam chain tensioner screw clockwise to

release the chain tension.

KM704A

3. Using a crisscross pattern, loosen the four nuts secur-

ing the camshaft holder to the cylinder head. Use 2-3

steps until the nuts are all free; then remove the cam-

shaft holder. Account for four washers and two

alignment pins.

AT THIS POINT

To service any one specific component, only limited dis-

assembly of components may be necessary. Note the

AT THIS POINT information in each sub-section.

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KM706A

KM707A

4. Remove the camshaft gear from the cam chain; then

secure the timing chain so it will not fall into the

engine. Remove the camshaft.

5. Remove the two external cap screws securing the

cylinder head to the cylinder; then remove the cylin-

der head. Account for two alignment pins and a cyl-

inder head gasket.

KM718A

6. Remove the cam chain guide; then disconnect the

coolant hose and remove the cylinder. Support the

piston with rubber bands or other suitable supports.

Account for two dowel pins and the cylinder gasket.

KM450

C. Cylinder

D. Piston

NOTE: Steps 1-6 in the preceding sub-section must

precede this procedure.

7. Using a needle nose pliers, remove one piston pin

circlip. Take care not to drop it into the crankcase.

KM451

8. Using Piston Pin Puller, remove the piston pin.

Account for the opposite-side circlip. Remove the

piston.

NOTE: It is advisable to remove the opposite-side

circlip prior to using the puller.

AT THIS POINT

To service valves and cylinder head, see Servicing Top-

Side Components sub-section.

AT THIS POINT

To inspect cam chain guide, see Servicing Top-Side

Components sub-section.

AT THIS POINT

To service cylinder, see Servicing Top-Side Compo-

nents sub-section.

CAUTION

When removing the cylinder, be sure to support the pis-

ton to prevent damage to the crankcase and piston.

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NOTE: Support the connecting rod with rubber

bands to avoid damaging the rod or install a connect-

ing rod holder.

NOTE: If the existing rings will not be replaced with

new rings, note the location of each ring for proper

installation. When replacing with new rings, replace

as a complete set only. If the piston rings must be

removed, remove them in this sequence.

A. Starting with the top ring, slide one end of the ring

out of the ring-groove.

B. Remove each ring by working it toward the dome

of the piston while rotating it out of the groove.

Servicing Top-Side

Components

NOTE: Whenever a part is worn excessively, cracked,

or damaged in any way, replacement is necessary.

VALVE ASSEMBLY

When servicing valve assembly, inspect valve seats,

valve stems, valve faces, and valve stem ends for pits,

discoloration, or other signs of abnormal wear.

NOTE: Whenever a valve is out of tolerance, it must

be replaced.

Cleaning/Inspecting Camshaft

Holder

1. Remove the rocker arm shafts, rocker arms, and stop

plate from the camshaft holder.

KM708A

2. Inspect the camshaft holder for cracks, distortion, or

galling.

3. Inspect the rocker arm shafts for blue discoloration

or scoring.

4. Inspect the rocker arms for excessive wear, loose

adjusters, or scored camshaft followers.

KM710A

Removing Valves

NOTE: Keep all valves and valve components as a

set. Note the original location of each valve set for

use during installation. Return each valve set to its

original location during installation.

1. Using a valve spring compressor, compress the valve

springs and remove the valve cotters. Account for an

upper spring retainer.

KM717A

2. Remove the valve seal, valve springs, and the lower

remaining spring seat. Discard the valve seal.

NOTE: The valve seals must be replaced.

3. Invert the cylinder head and remove the valves.

Measuring Valve Stem/Valve Guide

Clearance

1. Using a micrometer, measure the valve stem outside

diameter; then using a suitable snap gauge and

micrometer, measure the valve guide inside diameter.

2. Acceptable clearance must be within specifications.

Inspecting Valve Face

Inspect the valve face for pitting, grooving, or discolor-

ation. Replace any valve that is damaged.

CAUTION

Do not allow the connecting rod to go down inside the

crankcase. If the rod is down inside the crankcase and

the crankshaft is rotated, severe damage will result.

AT THIS POINT

To service piston, see Servicing Top-Side Components

sub-section.

AT THIS POINT

To service center crankcase components only, proceed

to Removing Left-Side Components.

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CYLINDER HEAD ASSEMBLY

NOTE: If the cylinder head cannot be trued, it must

be replaced.

Cleaning/Inspecting Cylinder Head

1. Using a non-metallic carbon removal tool, remove

any carbon build-up from the combustion chamber

making sure not to nick, scrape, or damage the com-

bustion chamber or the sealing surface.

2. Inspect the spark plug hole for any damaged threads.

Repair damaged threads using a “heli-coil” insert.

3. Place the cylinder head on the surface plate covered

with #400 grit wet-or-dry sandpaper. Using light

pressure, move the cylinder head in a figure eight

motion. Inspect the sealing surface for any indication

of high spots. A high spot can be noted by a bright

metallic finish. Correct any high spots before assem-

bly by continuing to move the cylinder head in a fig-

ure eight motion until a uniform bright metallic

finish is attained.

Measuring Cylinder Head

Distortion

1. Remove any carbon buildup in the combustion

chamber.

2. Lay a straightedge across the cylinder head; then

using a feeler gauge, check the distortion factor

between the head and the straightedge.

3. Maximum distortion must not exceed specifications.

CC141D

Measuring Camshaft Lobe Height

1. Using a calipers, measure each cam lobe height.

ATV1013A

2. The lobe heights must not be less than minimum

specifications.

Inspecting Camshaft Bearing

Journal

1. Inspect the bearing journal for scoring, seizure

marks, or pitting.

2. If excessive scoring, seizure marks, or pitting is

found, the cylinder head assembly must be replaced.

Measuring Rocker Arm/

Shaft Clearance

1. Using a dial calipers, measure the inside diameter of

the rocker arm; then measure the outside diameter of

the rocker arm shaft.

2. Acceptable clearance must not exceed specifications.

Installing Valves

1. Apply grease to the inside surface of the valve seals;

then place a lower spring seat and valve guide seal

over each valve guide.

2. Insert each valve into its original valve location.

3. Install the valve springs with the closest coils toward

the cylinder head.

ATV-1011A

4. Place a spring retainer over the valve springs; then

using the valve spring compressor, compress the

valve springs and install the valve cotters.

CAUTION

Water or parts-cleaning solvent must be used in con-

junction with the wet-or-dry sandpaper or damage to

the sealing surface may result.

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KM717A

PISTON ASSEMBLY

NOTE: Whenever a piston, rings, or pin are out of

tolerance, they must be replaced.

Cleaning/Inspecting Piston

1. Using a non-metallic carbon removal tool, remove

any carbon buildup from the dome of the piston.

2. Inspect the piston for cracks in the piston pin, dome,

and skirt areas.

3. Inspect the piston for seizure marks or scuffing.

Repair with #400 grit wet-or-dry sandpaper and

water or honing oil.

NOTE: If scuffing or seizure marks are too deep to

correct with the sandpaper, replace the piston.

4. Inspect the perimeter of each piston for signs of

excessive “blowby.” Excessive “blowby” indicates

worn piston rings or an out-of-round cylinder.

Removing Piston Rings

1. Starting with the top ring, slide one end of the ring

out of the ring-groove.

CC400D

2. Remove each ring by working it toward the dome of

the piston while rotating it out of the groove.

NOTE: If the existing rings will not be replaced with

new ones, note the location of each ring for proper

installation. When installing new rings, install as a

complete set only.

Cleaning/Inspecting Piston Rings

1. Take an old piston ring and snap it into two pieces;

then grind the end of the old ring to a 45° angle and

to a sharp edge.

2. Using the sharpened ring as a tool, clean carbon from

the ring-grooves. Be sure to position the ring with its

tapered side up.

Measuring Piston-Ring End Gap

(Installed)

1. Place each piston ring in the wear portion of the cyl-

inder. Use the piston to position each ring squarely in

the cylinder.

2. Using a feeler gauge, measure each piston-ring end

gap. Acceptable ring end gap must not exceed speci-

fications.

KM452

Measuring Piston Pin (Outside

Diameter) and Piston-Pin Bore

1. Measure the piston pin outside diameter at each end

and in the center. If measurement is not within speci-

fications, the piston pin must be replaced.

ATV-1070

2. Insert an inside dial indicator into the piston-pin

bore. The diameter must not exceed specifications.

Take two measurements to ensure accuracy.

CAUTION

Improper cleaning of the ring-grooves by the use of the

wrong type of ring-groove cleaner will result in severe

damage to the piston.

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ATV-1069

Measuring Piston Skirt/

Cylinder Clearance

1. Measure the cylinder front to back in six places.

CC397D

2. Measure the corresponding piston diameter at a point

18 mm above the piston skirt at a right angle to the

piston-pin bore. Subtract this measurement from the

measurement in step 1. The difference (clearance)

must be within specifications.

Installing Piston Rings

1. Install ring expander (4) in the bottom groove of the

piston; then install the thin oil rings (3) over the

expander making sure the expander ends do not

overlap. Stagger the end gaps of the upper and lower

thin oil rings according to the illustration.

NOTE: Note the direction of the exhaust side of the

piston (5) for correct ring end gap orientation.

ATV-1085B

2. Install the compression rings (1 and 2) so the letter

on the top surface of each ring faces the dome of the

piston. Rotate the rings until the ring end gaps are on

directly opposite sides of the piston according to the

illustration.

726-306A

CYLINDER ASSEMBLY

NOTE: If the cylinder cannot be trued, it must be

replaced.

Cleaning/Inspecting Cylinder

1. Wash the cylinder in parts-cleaning solvent.

2. Inspect the cylinder for pitting, scoring, scuffing,

warpage, and corrosion. If marks are found, repair

the surface using a cylinder hone (see Honing Cylin-

der in this sub-section).

3. Place the cylinder on the surface plate covered with

#400 grit wet-or-dry sandpaper. Using light pressure,

move the cylinder in a figure eight motion. Inspect

the sealing surface for any indication of high spots.

A high spot can be noted by a bright metallic finish.

Correct any high spots before assembly by continu-

ing to move the cylinder in a figure eight motion

until a uniform bright metallic finish is attained.

Inspecting Cam Chain Guide

1. Inspect cam chain guide for cuts, tears, breaks, or

chips.

2. If the chain guide is damaged, it must be replaced.

Honing Cylinder

1. Using a slide gauge and a dial indicator or a snap

gauge, measure the cylinder bore diameter in three

locations from top to bottom and again from top to

bottom at 90° from the first measurements for a total

of six measurements. The trueness (out-of-round-

ness) is the difference between the highest and low-

est reading. Maximum trueness (out-of-roundness)

must not exceed specifications.

CAUTION

Incorrect installation of the piston rings will result in

engine damage.

CAUTION

Water or parts-cleaning solvent must be used in con-

junction with the wet-or-dry sandpaper or damage to

the sealing surface may result.

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CC127D

2. Wash the cylinder in parts-cleaning solvent.

3. Inspect the cylinder for pitting, scoring, scuffing, and

corrosion. If marks are found, repair the surface

using a #320 grit ball hone.

NOTE: To produce the proper 60° cross-hatch pat-

tern, use a low RPM drill (600 RPM) at the rate of 30

strokes per minute. If honing oil is not available, use

a lightweight petroleum-based oil. Thoroughly clean

cylinder after honing using soap and hot water. Dry

with compressed air; then immediately apply oil to

the cylinder bore. If the bore is severely damaged or

gouged, replace the cylinder.

CC390D

4. If any measurement exceeds the limit, replace the

cylinder.

Installing Top-Side

Components

A. Piston

B. Cylinder

1. Install the piston on the connecting rod making sure

there is a circlip on each side and the open end of the

circlip is directed upwards or downwards.

NOTE: The piston should be installed so the IN

mark is toward the intake (rear) side of the cylinder.

2. Place the two alignment pins into position. Place the

cylinder gasket into position; then place a piston

holder (or suitable substitute) beneath the piston skirt

and square the piston in respect to the crankcase.

3. Lubricate the inside wall of the cylinder; then using a

ring compressor or the fingers, compress the rings

and slide the cylinder over the piston. Route the cam

chain up through the cylinder cam chain housing;

then remove the piston holder and seat the cylinder

firmly on the crankcase.

4. Turn the cam chain tensioner screw clockwise to

retract the tensioner spring.

KM705

C. Cylinder Head

D. Valve Cover

NOTE: Steps 1-4 in the preceding sub-section must

precede this procedure.

5. While keeping tension on the cam chain, place the

front cam chain guide into the cylinder.

6. Place the head gasket into position on the cylinder.

Place the alignment pins into position; then place the

head assembly into position on the cylinder making

sure the cam chain is routed through the chain cavity.

KM718A

CAUTION

The cylinder should slide on easily. Do not force the cyl-

inder or damage to the piston, rings, cylinder, or crank-

shaft assembly may occur.

CAUTION

Care should be taken that the bottom of the chain guide

is secured in the crankcase boss.

CAUTION

Keep tension on the cam chain to avoid damaging the

crankcase boss.

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7. Turn the crankshaft as required to align the “T” mark

on the rotor/flywheel with the index mark on the

right-side crankcase cover.

KM779A

8. With the index hole in the camshaft gear directed

away from the cylinder head and the two punch

marks aligned with the cylinder head surface, install

the timing gear into the cam chain and seat the cam-

shaft into the camshaft journals.

KM715A

9. Install the two alignment pins; then install the cam-

shaft holder and secure with the four cylinder head

nuts and washer. Using a crisscross pattern, tighten

to 18 ft-lb.

KM707A

KM706A

10. Install the cam chain tensioner assembly and tighten

the mounting cap screws to 9 ft-lb; then turn the ten-

sioner screw counterclockwise to tension the cam

chain.

KM705

11. Install the cam chain tensioner cover bolt and tighten

to 24 in.-lb.

12. Check that the cam gear alignment marks are cor-

rectly oriented; then install and tighten the external

cylinder head to cylinder cap screws to 7 ft-lb.

13. Install the cylinder head cover with a new O-ring and

tighten securely.

KM703

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Left-Side Components

NOTE: For efficiency, it is preferable to remove and

disassemble only those components which need to

be addressed and to service only those components.

The technician should use discretion and sound

judgment.

NOTE: The engine/transmission does not have to

be removed from the frame for this procedure.

Removing Left-Side

Components

A. Recoil Starter (Utility)

1. Remove the five recoil starter cover cap screws.

Remove the recoil starter assembly noting the loca-

tion of the dowel pins. Note the condition of the

recoil cover gasket. Replace if damaged.

B. V-Belt Cover

C. Drive Pulley

D. Driven Pulley/Centrifugal Clutch

Assembly

NOTE: On the Utility, step 1 in the preceding sub-

section must precede this procedure.

2. Remove the ten cap screws securing the V-belt

cover; then remove the cover noting the location of

the two dowel pins. Note the condition of the V-belt

cover gasket. Replace if damaged.

KM253

3. On the Utility using a suitable holder to prevent the

drive pulley from turning, remove the drive face nut

and starter ratchet; then remove the drive pulley face.

KM365

4. Hold the centrifugal clutch with a suitable holder;

then remove the clutch retaining nut and clutch collar.

KM364

5. Remove the outer clutch housing; then remove the

centrifugal clutch, driven pulley, and V-belt.

KM369

6. Remove the drive pulley collar and the movable

drive face taking care not to loose the rollers.

Servicing Left-Side

Components

RECOIL STARTER (Utility)

AT THIS POINT

To service any one specific component, only limited dis-

assembly of components may be necessary. Note the

AT THIS POINT information in each sub-section.

AT THIS POINT

To service the recoil starter, see Servicing Left-Side

Components sub-section.

! WARNING

Always wear safety glasses when servicing the recoil

starter.

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Removing/Disassembling

1. Remove the cap screws securing the recoil starter

assembly to the V-belt cover; then remove the starter.

Account for two alignment pins.

KM413A

2. Rotate the reel clockwise until the notch of the reel is

near the rope guide in the case. Guide the rope into

the notch and slowly allow the reel to unwind until

all spiral spring tension is released.

3. Remove the cap screw. Account for the ratchet

guide, spacer, and spring.

KM411

4. Carefully lift the reel free of the case making sure the

spiral spring does not accidentally disengage from

the case.

KM402A

5. Remove the protective cover from the starter handle

and pull the rope out of the handle; then untie the

knot in the rope and remove the handle. Account for

a flat washer.

KM408

NOTE: Do not remove the spiral spring unless

replacement is necessary. It should be visually

inspected in place to save time. If replacement is nec-

essary, follow steps 6-7.

6. Remove the spiral spring from the case by lifting the

spring end up and out. Hold the remainder of the

spring with thumbs and alternately release each

thumb to allow the spring to gradually release from

the case.

7. Unwind the rope from the reel and remove the rope.

Cleaning and Inspecting

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is nec-

essary.

1. Clean all components.

2. Inspect the springs and ratchet for wear or damage.

3. Inspect the reel and case for cracks or damage.

4. Inspect the shaft for wear, cracks, or damage.

5. Inspect the rope for breaks or fraying.

6. Inspect the spiral spring for cracks, crystallization, or

abnormal bends.

! WARNING

During the disassembling procedure, continuous back-

ward pressure must be exerted on the reel so it does

not accidentally unwind and cause injury.

CAUTION

During the disassembling procedure, make sure all

spring tension is released before continuing.

! WARNING

Care must be taken when lifting the reel free of the case.

Wear safety glasses to avoid injury.

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7. Inspect the handle for damage, cracks, or deteriora-

tion.

Assembling/Installing

1. If removed, insert the spiral spring into the case with

the outer end of the spring around the mounting lug

in the case; then wind it in a counterclockwise direc-

tion until the complete spring is installed.

NOTE: The spiral spring must seat evenly in the

recoil case.

KM402

2. Insert the rope through the hole in the reel and tie a

knot in the end; then wrap the rope clockwise around

the reel leaving approximately 50 cm (20 in.) of rope

free of the reel.

3. Apply low-temperature grease to the spring and hub.

4. Thread the end of the rope through the guide hole of

the case; then thread the rope through the handle and

washer and secure it with a double knot. Install the

protective cover into the handle.

KM400

KM405

5. Align the inner hook of the spiral spring with the

notch in the reel spacer.

KM402A

6. Install the ratchets making sure the ends are properly

oriented on the reel.

KM397A

7. Install the spacer, spring, and the ratchet guide mak-

ing sure the ratchet pins engage the guide.

KM401

8. Hold the ratchet guide down in place on the ratchet

pins and secure with the cap screw coated with blue

Loctite #243. Tighten securely.

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KM410

9. With the 50 cm (20 in.) of rope exposed, hook the

rope in the notch of the reel.

10. Rotate the reel four turns clockwise; then release the

rope from the notch and allow the rope to retract.

11. Pull the rope out two or three times to check for cor-

rect tension and ratchet extender.

KM412

NOTE: Increasing the rotations in step 10 will

increase spring tension.

12. Place the recoil starter assembly into position on the

left-side cover; then tighten the cap screws to securely.

V-BELT COVER

1. Inspect the bearing for excessive wear, rough or

binding when turning, seal condition, and secure

mounting in the V-belt cover.

NOTE: If the bearing is worn excessively, turns

roughly, or bearing seals are loose, the bearings

must be replaced.

KM254

2. Inspect the V-belt cover for cracks, distortion, and

loose alignment pins.

NOTE: If the V-belt cover is cracked or distorted or if

the bearing is loose in the cover, the cover must be

replaced.

DRIVE PULLEY

1. Remove the ramp plate from the movable drive face;

then inspect the ramp plate guides and weight roller

for damage or excessive wear.

KM256

2. Inspect the face surfaces of the fixed and movable

drive faces for grooving, nicks, or discoloration.

KM394A

3. Inspect the drive pulley collar for wear or damage.

Measure the outside diameter of the drive pulley col-

lar sliding surface. The minimum service limit is

26.94 mm.

KM389

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DRIVEN PULLEY/CENTRIFUGAL

CLUTCH ASSEMBLY

Disassembling

1. Place the driven pulley on a suitable spring compres-

sor; then mark the pulley faces and centrifugal clutch

for alignment during assembling.

KM374A

2. Secure the centrifugal clutch with the spring com-

pressor; then remove the drive plate nut.

KM373

3. Release the spring pressure and remove the centrifu-

gal clutch assembly from the driven pulley.

KM375

4. Remove the spring and spring seat; then remove the

hub collar.

KM385

5. Remove four pins and bushings from the fixed face

hub; then remove the movable face.

KM384

KM380

Inspecting

1. Inspect the pulley faces for wear, galling, or groov-

ing.

KM394A

! WARNING

This procedure involves relaxing a compressed spring

assembly. DO NOT attempt disassembling without the

proper tools.

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2. Inspect the O-rings on the movable face for nicks,

tears, or swelling.

KM380A

3. Inspect two grease seals in the movable face for

nicks, cuts, or damage.

KM380B

KM382A

4. Inspect the pins and bushings for wear, flat spots,

looseness, or cracking.

KM379

5. Measure the driven face spring free length. If the free

length is less than 131 mm, the spring must be

replaced.

KM376

6. Measure the driven fixed face hub using a calipers.

The minimum service limit is 39.93 mm.

KM378

7. Measure the thickness of the centrifugal clutch shoe

lining. The minimum service limit for the lining is

0.5 mm.

NOTE: If any shoe lining is below the service limit,

the complete set must be replaced.

Assembling

1. Place the fixed face of the driven pulley on the pulley

compressor base.

NOTE: Make sure the spacer is on the base or dam-

age to the fixed face will occur when the spring is

compressed.

KX571

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2. Apply multi-purpose grease to the O-rings and

grease seals on the movable face; then install on the

fixed face making sure the alignment marks are

properly aligned.

KM374A

3. Install the pins and spacers into the fixed face hub;

then pack the cam slots in the movable face with

multi-purpose grease.

KM384

4. Install the spring seat over the hub and movable face

hub.

KM385

5. Place the spring holder on the spring; then install the

spring on the pulley assembly.

KM386

6. Place the centrifugal clutch assembly, drive plate nut,

and clutch compressor adapter in position; then using

the clutch compressor wing nut, compress the clutch

spring and install the nut (lightly coated with red

Loctite #271).

KM373

7. Using a suitable holding fixture, tighten the drive

plate nut (coated with red Loctite #271) to 43 ft-lb.

Installing Left-Side

Components

A. Drive Pulley

B. Driven Pulley/Centrifugal Clutch

Assembly

C. V-Belt Cover

1. Install the movable drive face and drive pulley collar

on the crankshaft.

2. Open the faces of the driven pulley; then insert a

suitable wedge between the faces to hold them apart.

3. Place the V-belt around the pulley and push the belt

down between the pulley faces; then install the

driven pulley/centrifugal clutch assembly onto the

driveshaft. Loop the V-belt over the drive pulley col-

lar.

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KM262

KM369

4. Place the fixed drive face into position on the crank-

shaft and engage the splines making sure the splines

extend beyond the pulley face hub.

KM263A

5. On the Utility, install the starter ratchet on the crank-

shaft making sure to engage the splines; then secure

with the flange nut and tighten to 68 ft-lb.

KM366

KM365

6. Install the centrifugal clutch housing and clutch collar;

then secure with the flange nut and tighten to 40 ft-lb.

KM253

KM368

7. Install the alignment pins and a new gasket on the

crankcase; then install the V-belt cover and secure

with the cap screws. Tighten securely.

8. On the Utility, install the recoil starter and secure

with the cap screws. Tighten securely.

Right-Side Components



NOTE: For efficiency, it is preferable to remove and

disassemble only those components which need to be

addressed and to service only those components. The

technician should use discretion and sound judgment.

 AT THIS POINT

To service center crankcase components only, proceed

to Removing Right-Side Components.

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NOTE: The engine/transmission does not have to

be removed from the frame for this procedure.

Removing Right-Side

Components

A. Transmission (DVX)

1. Drain the transmission lubricant into a suitable con-

tainer; then install the drain plug and tighten to 21 ft-

lb.

KM106

2. Remove the drive sprocket cover; then remove the

cap screws and lock plate securing the sprocket to

the driveshaft and remove the sprocket.

KM344A

3. Remove the cap screws securing the transmission

case cover to the transmission; then remove the

cover. Account for the dowel pins and gasket.

KM609A

4. Remove the output driveshaft circlip; then remove

the driveshaft from the transmission case cover.

KM611A

5. Remove the shift shaft; then remove the plug.

Account for one shift cam stopper ball, spring, and

seal/washer.

KM677A

KM619A

AT THIS POINT

To service any one specific component, only limited dis-

assembly of components may be necessary. Note the

AT THIS POINT information in each sub-section.

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6. Remove the shift fork guide shaft; then hold the shift

fork away from the shift cam and remove the shift cam.

KM620A

KM621

7. Remove the shift fork; then remove the main shaft

assembly.

KM622A

8. Remove the countershaft; then remove the primary

drive axle.

KM627B

A. Transmission (Utility)

1. Drain the transmission lubricant into a suitable con-

tainer; then install the drain plug and tighten to 21 ft-

lb.

KM106

NOTE: If the engine has not been removed, remove

the swing arm assembly (see Suspension).

2. Using a crisscross pattern, remove four cap screws

securing the secondary driven bevel gear assembly to

the transmission case cover; then remove the assem-

bly. Account for an O-ring.

KM646A

3. Remove the three cap screws securing the secondary

drive bevel gear cover; then remove the cover.

Account for a gasket.

KM648A

4. Remove the speedometer gear retainer nut, washer,

and speedometer gear.

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KM649

5. Using a Spanner Wrench to hold the centrifugal

clutch housing, remove the nut securing the second-

ary drive bevel gear to the driveshaft.

KM650

NOTE: If the engine has been removed and the left-

side components are removed, install the centrifugal

clutch housing on the driveshaft. If the left-side com-

ponents have not been removed, see Removing Left-

Side Components in this section. Remove only the V-

belt cover.

6. Remove the eight cap screws securing the transmis-

sion case cover to the transmission case; then remove

the cover. Account for a gasket (A), the secondary

drive bevel gear, washer (B), and two alignment pins

(C).

KM651A

KM652A

7. Remove the shift shaft; then remove plug, seal/

washer, spring, and shift cam stopper ball.

KM677A

KM619A

8. Remove the shift fork guide shaft; then remove the

upper shift fork and shift cam.

KM679A

9. Remove the lower shift fork.

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KM680

10. Remove the countershaft and driveshaft as an assembly.

KM681

11. To disassemble the countershaft, use the following

procedure.

A. Remove the thrust washer and high gear clutch

dog.

KM684

B. Remove the high drive gear circlip and washer;

then remove the high drive gear and thrust

washer.

KM685

12. To disassemble the driveshaft, use the following pro-

cedure.

A. Remove the thrust washer; then remove the

reverse gear.

KM689A

B. Remove a thrust washer and the low/reverse

clutch dog.

KM690A

C. Remove the low driven gear snap ring and

washer; then remove the low driven gear and

thrust washer.

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KM692A

13. To disassemble the secondary driven bevel gear

assembly, use the following procedure.

A. Secure the universal joint using a suitable vise;

then engage the output end of the shaft with the

universal joint.

KM653

B. Remove the nut securing the driven bevel gear;

then remove the gear. Account for a washer.

KM654

C. Remove the shaft and housing from the universal

joint and remove the shaft from the housing.

NOTE: If left-side components are still attached,

remove the centrifugal clutch/driven pulley (see

Removing Left-Side Components in this section).

B. Water Pump

C. Trigger Coil

D. Stator Coil

E. Rotor/Flywheel

14. Remove the right crankcase cover (see Fuel/Lubrica-

tion/Cooling - Water Pump).

15. Remove the trigger coil mounting screws; then

remove the wire set plate.

KM772A

16. Remove the three cap screws securing the stator coil

to the crankcase cover; then remove the stator coil

and trigger coil.

17. Remove the oil-through and spring from the end of

the crankshaft; then hold the rotor/flywheel with an

appropriate holding tool and remove the flywheel nut

and washer.

KM774

18. Install the flywheel puller and crankshaft protector;

then remove the rotor/flywheel. Account for a key

and the starter one-way clutch bearing.

AT THIS POINT

To remove/service the water pump, see Fuel/Lubrica-

tion/Cooling.

CAUTION

Use extreme care to avoid damaging or shorting the

wiring.

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KM775

KM766A

NOTE: The starter one-way clutch bearing is direc-

tion oriented and will only function if installed prop-

erly. Note the markings or arrows when removed.

F. Oil Pump

NOTE: Steps 14-18 in the preceding sub-section

must precede this procedure.

19. Remove the rotor/flywheel (see Rotor/Flywheel in

this sub-section).

20. Remove the starter drive gear and place together

with the rotor/flywheel to keep the one-way clutch

bearing intact.

KM767A

KM766A

21. Remove the two cap screws securing the oil baffle to

the crankcase and remove the baffle; then remove the

snap ring securing the oil pump driven sprocket.

KM428

KM429

22. Remove the oil pump drive chain and oil pump

driven sprocket.

23. Remove the two cap screws securing the oil pump to

the crankcase and remove the oil pump.

Servicing Right-Side

Components

NOTE: Whenever a part is worn excessively,

cracked, damaged in any way, or out of tolerance,

replacement is necessary.

AT THIS POINT

To service the stator coil, see Electrical System.

AT THIS POINT

To service the trigger coil, see Electrical System.

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TRANSMISSION (DVX)

Inspecting

1. Measure the shift fork guide shaft runout. If runout

exceeds 0.03 mm, the shaft must be replaced.

KM623

2. Inspect the shift forks for distortion, discoloration,

scoring, or excessive wear.

3. Inspect the shift cam groove and shift cam gear for

excessive wear.

KM625

4. Inspect shift shaft and shift shaft gear for excessive

wear.

KM626

5. Inspect all gear teeth for chipping, discoloration, pit-

ting, or excessive wear. Replace as required.

6. Inspect clutch dogs and mating surfaces for chip-

ping, rounding, or excessive wear. Replace as

required.

KM628

7. Inspect all bearings, bushings, seals, and shafts for

proper fit, surface mating, or discoloration. Replace

as required.

8. Inspect transmission housing and cover for cracks,

scoring or galling of bearing bores, or discoloration

of cases.

Assembling

1. Place the thrust washer, needle bearing, reverse gear,

and splined retainer onto the main shaft; then secure

with the circlip.

KM631A

2. Install the clutch dog, splined washer, bushing, and

primary driven gear onto the main shaft; then install

the second splined washer, spacer collar, and thrust

washer. The main shaft is now assembled and can be

installed.

KM629A

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KM628

3. Install the drive axle into the transmission housing;

then secure with the circlip.

KM611A

4. Apply multi-purpose grease to the lip of the main

drive seal; then using a suitable driver, install the seal

into the gear case.

5. Install the countershaft; then making sure the main

shaft thrust washer is in place, install the main shaft

assembly into the gear case.

KM613A

6. Install the shift shaft making sure the pin in the gear

position switch engages the slot in the shift shaft and

the shift shaft gear is correctly timed to the shift cam.

KM617A

7. Install the shift cam stopper ball, spring, seal/washer,

and plug (threads coated with red Loctite #271).

Tighten to 35 ft-lb.

KM619A

TRANSMISSION (Utility)

Inspecting

1. Measure the shift fork guide shaft runout. If runout

exceeds 0.03 mm, the shaft must be replaced.

KM623

2. Inspect the shift forks for distortion, discoloration, or

excessive wear.

3. Inspect the shift cam groove and shift cam gear for

excessive wear.

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KM624

4. Inspect the shift shaft and gear for excessive wear.

Check that the spring is not broken.

KM683

5. Inspect all gear teeth for chipping, discoloration, pit-

ting, or excessive wear. Replace as required.

6. Inspect clutch dogs and mating surfaces for chip-

ping, rounding, or excessive wear. Replace as

required.

7. Inspect all bearings, bushings, seals, and shafts for

proper fit, surface mating, or discoloration. Replace

as required.

8. Inspect transmission housing and cover for cracks,

scoring or galling of bearing bores, or case discolor-

ation.

9. Inspect the drive and driven bevel gears for chipping,

flaking, or excessive wear in the splines. Replace as

required.

KM422

10. Inspect the secondary driven bevel gear housing for

cracks, loose bearings, or signs of discoloration from

heat. Replace as required.

11. Inspect the driven shaft for scoring, discoloration, or

worn splines.

KM421

SECONDARY GEARS

Checking Backlash

1. Remove the secondary drive bevel gear cover.

2. Mount a dial indicator so as to allow the tip to con-

tact the secondary driven bevel gear.

3. Mount the indicator tip of the dial indicator on the

secondary driven bevel gear (centered on the gear

tooth).

4. While rocking the driven bevel gear back and forth,

note the maximum backlash reading on the gauge.

5. Acceptable backlash range is 0.03-0.15 mm (0.001-

0.006 in.).

Correcting Backlash

NOTE: If backlash measurement is within the

acceptable range, no correction is necessary.

1. If backlash measurement is less than specified,

remove an existing driven bevel gear shim, measure

it, and install a new thinner shim.

2. If backlash measurement is more than specified,

remove an existing driven bevel gear shim, measure

it, and install a thicker shim.

NOTE: Continue to remove, measure, and install

until backlash measurement is within tolerance. Note

the following chart.

Checking Tooth Contact

NOTE: After correcting backlash of the secondary

driven bevel gear, it is necessary to check tooth con-

tact.

1. Remove the secondary driven output shaft assembly

from the left-side crankcase half.

Backlash Measurement Shim Correction

Under 0.03 mm (0.001 in.) Decrease Shim

Thickness

At 0.03-0.15 mm

(0.001-0.006 in.)

No Correction Required

Over 0.15 mm (0.006 in.) Increase Shim

Thickness

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2. Clean the secondary driven bevel gear teeth of old oil

and grease residue.

3. Apply a thin, even coat of a machinist-layout dye to

several teeth of the gear.

4. Rotate the secondary driven bevel gear several revo-

lutions in both directions.

5. Examine the tooth contact pattern in the dye and

compare the pattern to the illustrations.

ATV-0103

ATV-0105

ATV-0104

Correcting Tooth Contact



NOTE: If tooth contact pattern is comparable to the

correct pattern illustration, no correction is necessary.

If tooth contact pattern is comparable to an incorrect pat-

tern, correct tooth contact according to the following chart.



NOTE: To correct tooth contact, increase or decrease

shims as necessary on both secondary drive and

driven gears equally. Use the “Tooth Contact/Shim

Correction” chart above for shim selections.

Assembling

1. Using the appropriate bearing and seal drivers,

install any required bearings and seals in the trans-

mission case and case cover.

KM696

2. Replace any required bearings and seals in the sec-

ondary driven bevel gear shaft case. Apply oil to all

seal lips.

KM695

3. Apply oil to the secondary driven bevel gear shaft;

then install the bearing into the case.

KM420

Tooth Contact Shim Correction

Contacts at Top Increase Shim Thickness

Contacts at Root Decrease Shim Thickness

CAUTION

After correcting tooth contact, backlash must again be

checked and corrected (if necessary). Continue the cor-

recting backlash/correcting tooth contact procedures

until they are both within tolerance values.

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4. Install the flat thrust washer and driven bevel gear on

the driven shaft; then using the universal joint and

vise to hold the shaft, install a new nut and tighten to

72 ft-lb.

KM425

5. Use a center punch to stake the nut to the driven

shaft.

KM426A

6. Install the high drive gear thrust washer on the coun-

tershaft; then install the high drive gear and secure

with a circlip.

KM685A

7. Install the high gear clutch dog and flat washer. At

this point, the countershaft is ready for installation.

KM684

8. Install the low driven gear washer on the driveshaft;

then install the low driven gear and thrust washer.

Secure with a snap ring.

KM692A

9. Install the low/reverse clutch dog and spacer washer;

then install the reverse gear and reverse gear thrust

washer. At this point, the driveshaft is ready for

installation.

KM690A

10. Apply clean engine oil to the assembled shafts and

gears; then install the countershaft and driveshaft

simultaneously into the transmission case.

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KM699

11. Install the low/reverse shift fork into the low/reverse

clutch dog; then install the shift cam into the trans-

mission case and engage the shift fork pawl in the

appropriate shift cam groove.

KM700

12. Install the high shift fork into the high clutch dog;

then engage the shift fork pawl into the appropriate

shift cam groove.

13. Install the shift fork shaft making sure that the shift

fork pawls remain engaged in the shift cam; then

install the shift cam stopper ball, spring, seal/washer,

and plug (threads coated with red Loctite #271).

Tighten to 20 ft-lb.

KM619A

14. Install the shift shaft making sure to align the timing

mark between the two marks on the shift cam.

KM702A

15. Install the two alignment pins, gasket, and transmis-

sion case cover and secure with eight cap screws.

Tighten in a crisscross pattern to 20 ft-lb.

KM651A

16. Install a spacer washer and the drive bevel gear on

the driveshaft; then while holding the centrifugal

clutch housing with an appropriate holder, secure the

bevel gear with a new nut and tighten to 72 ft-lb.

KM650

17. Use a center punch to stake the nut to the driveshaft.

18. Apply clean engine oil to a new O-ring and install in

the groove of the secondary driven bevel gear hous-

ing; then with the index marks aligned, install the

secondary driven bevel gear assembly in the trans-

mission case.

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KM673

19. Loosely secure the secondary driven bevel gear

assembly using the four cap screws; then using a

crisscross pattern, tighten the cap screws until fully

seated in the transmission housing.

KM646A

Installing Right-Side

Components

A. Oil Pump

1. Install the oil pump with the arrow on the pump body

directed upward; then secure with the two cap screws

and tighten securely. Make sure the shaft turns freely

after installing.

KM434A

2. Install the oil pump driven sprocket and drive chain;

then secure the driven sprocket with a snap ring.

3. Install the oil pump baffle and tighten the cap screws

securely.

B. Rotor/Flywheel

C. Trigger Coil

D. Stator Coil

4. Install the starter idler shaft and gear in the crank-

case; then install the starter driven gear on the crank-

shaft.

KM767

NOTE: Make sure the crankshaft and rotor/flywheel

contact surfaces are clean and dry before installing

the flywheel.

5. Install the key in the crankshaft; then with the starter

one-way bearing correctly installed, place the rotor/

flywheel onto the crankshaft and position the align-

ing keyway with the key.

6. Secure the rotor/flywheel on the crankshaft with the

nut and tighten to 47 ft-lb; then install the spring and

oil-through in the crankshaft.

KM773A

7. Install the trigger coil and stator coil in the right-side

crankcase cover; then secure with the existing hard-

ware and tighten securely.

E. Water Pump

F. Transmission

See Servicing Right-Side Components in this sub-section.

AT THIS POINT

To install the water pump, see Fuel/Lubrication/Cooling.

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Center Crankcase

Components

NOTE: This procedure cannot be done with the

engine/transmission in the frame. Complete Remov-

ing procedures for Top-Side, Left-Side, and Right-

Side must precede this procedure.



NOTE: For efficiency, it is preferable to remove and

disassemble only those components which need to be

addressed and to service only those components. The

technician should use discretion and sound judgment.

Separating Crankcase

Halves

1. Remove the left-side and right-side cap screws

securing the crankcase halves noting the position of

the different-sized cap screws for joining purposes.

KM720A

2. Using Crankcase Separator/Crankshaft Remover and

tapping lightly with a rubber mallet, separate the

crankcase halves. Account for two alignment pins

and a gasket.

Disassembling Crankcase

Half

1. Remove the crankshaft from the left crankcase half.

KM721

2. Remove the balancer shaft from the left crankcase

half.

KM722

Servicing Center

Crankcase Components

NOTE: Whenever a part is worn excessively,

cracked, damaged in any way, or out of tolerance,

replacement is necessary.

CRANKSHAFT ASSEMBLY

Measuring Connecting Rod

(Small End Inside Diameter)

1. Insert a snap gauge into the upper connecting rod

small end bore; then remove the gauge and measure

it with micrometer.

AT THIS POINT

To service crankshaft assembly, see Servicing Center

Crankcase Components sub-section.

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CC290D

2. Maximum diameter must not exceed specifications.

Measuring Connecting Rod

(Small End Deflection)

1. Place the crankshaft on a set of V-blocks and mount a

dial indicator and base on the surface plate. Position

the indicator contact point against the center of the

connecting rod small end journal.

2. Zero the indicator and push the small end of the con-

necting rod away from the dial indicator.

3. Maximum deflection must not exceed specifications.

Measuring Connecting Rod

(Big End Side-to-Side)

1. Push the lower end of the connecting rod to one side

of the crankshaft journal.

2. Using a feeler gauge, measure the gap between the

connecting rod and crankshaft journal.

CC289D

3. Acceptable gap range must be within specifications.

Measuring Crankshaft (Runout)

1. Place the crankshaft on a set of V blocks.

2. Mount a dial indicator and base on the surface plate.

Position the indicator contact at point 1 of the crank-

shaft.

ATV-1074

3. Zero the indicator and rotate the crankshaft slowly.

4. Maximum runout must not exceed specifications.

NOTE: Proceed to check runout on the other end of

the crankshaft by positioning the indicator contact at

point 2 and following steps 3-4.

Measuring Crankshaft (Web-to-

Web)

1. Using a calipers, measure the distance from the out-

side edge of one web to the outside edge of the other

web.

ATV-1017

2. Acceptable width range must be within specifica-

tions.

CRANK BALANCER SHAFT

Inspecting

Inspect the gear teeth and bearing surfaces for chips, dis-

coloration, or excessive wear.

CAUTION

Care should be taken to support the connecting rod

when rotating the crankshaft.

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KM724

Assembling Crankcase

Half

NOTE: For ease of assembling, install components

on the left-side crankcase half.

To assemble center crankcase components, install the

balancer shaft into the left-side crankcase half; then align

the timing mark on the balancer shaft with the timing

mark on the crankshaft. Install the crankshaft.

KM728A

Joining Crankcase Halves

1. Verify that the alignment pins and a new gasket are

in place and that both case halves are clean and

grease free. Place the right-side half onto the left-

side half.

2. Using a plastic mallet, lightly tap the case halves

together until cap screws can be installed.

3. From the right side, install the crankcase cap screws

noting the location of the different-sized cap screws;

then tighten only until snug.

NOTE: Rotate the crankshaft back and forth to

ensure no binding or sticking occurs while tightening

the cap screws.

MD1008

4. From the left side, install the remaining crankcase

cap screws; then tighten only until snug.

NOTE: Rotate the crankshaft back and forth to

ensure no binding or sticking occurs while tightening

the cap screws.

CC871

5. In a crisscross/case-to-case pattern, tighten the cap

screws until the halves are correctly joined; then

tighten to 8 ft-lb.

NOTE: Rotate the crankshaft back and forth to

ensure no binding or sticking occurs.

Installing Engine/

Transmission

DVX

1. Attach a suitable engine lift to the front engine

mounting boss; then lift the engine/transmission into

the frame from the left side. The front of the engine/

transmission should go in first.

2. Lifting the front of the engine/transmission, move

the assembly forward sufficiently to clear the rear

engine mounts; then slide the engine/transmission

into the rear mounts.

AT THIS POINT

After completing center crankcase components, pro-

ceed to Installing Right-Side Components, to Installing

Left-Side Components, and to Installing Top-Side Com-

ponents.

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3. Lower the engine/transmission and install the lower

rear and upper rear through-bolts and nuts. Finger

tighten only.

4. Remove the engine lift from the front mounting boss;

then install the left and right engine mounting brack-

ets and attach with the existing hardware. Finger

tighten only.

5. Install the front engine through-bolt and nut; then

tighten the engine mounting bracket cap screws to 16

ft-lb.

6. Tighten the engine through-bolt nuts to 29 ft-lb.

7. Connect the shift linkage to the shift arm and tighten

the nut securely.

8. Install the output drive sprocket and drive chain; then

secure with the lock plate and two cap screws.

Tighten to 43 ft-lb and bend the tabs up on the lock

plate.

KM344

9. Install the output drive sprocket cover with the exist-

ing hardware and tighten securely.

10. Connect the upper and lower coolant hoses to the

engine and secure with the clamps. Tighten securely.

11. Connect the front and rear cooling boots to the V-belt

housing and secure with the clamps. Tighten

securely.

12. Connect the starter wire to the starter stud and secure

with a washer and nut. Tighten securely.

13. Connect the stator connector, shift position connec-

tor, and the coolant temperature sensor; then secure

the engine ground cable to the engine and tighten the

cap screw securely.

KM347A

KM324A

14. Install the coil (see Electrical System).

15. Install the carburetor (see Fuel/Lubrication/Cooling).

16. Install the exhaust pipe/muffler assembly (see Steer-

ing/Frame).

17. Install the gas tank (see Fuel/Lubrication/Cooling).

18. Install the air filter housing (see Steering/Frame).

19. Install the body (see Steering/Frame).

20. Install the gas tank cover panel.

21. Install the electrical tray. Install the battery and con-

nect the positive cable; then connect the negative

cable.

22. Pour in the recommended amount and grade of

engine coolant, engine oil, and transmission lubri-

cant.

23. Install the seat.

Utility

1. Attach a suitable engine lift to the front engine

mounting boss; then lift the engine/transmission

assembly into the frame from the left side. The front

of the engine/transmission should go in first.

KM331

2. Lifting the front of the engine/transmission, move

the assembly forward sufficiently to clear the rear

engine mounts; then engage the secondary bevel

driveshaft into the universal joint splines.

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KM328

3. Slide the engine/transmission rearward into the rear

engine mounts; then install the rear through-bolts

and nuts. Do not tighten at this time.

4. Remove the engine lift from the front engine mount-

ing boss; then install the engine mounting brackets to

the frame. Finger tighten only.

KM414

5. Install the front engine through-bolt; then tighten the

engine mounting brackets to 16 ft-lb.

KM414A

6. Tighten the nuts on the two rear and one front

through-bolt to 29 ft-lb.

7. Connect the shift linkage using the existing hard-

ware.

8. Install the output drive boot onto the bevel driven

gear housing and secure with the existing clamp.

KM315A

9. Connect the V-belt cooling boots to the V-belt hous-

ing and secure with the existing hose clamps.

KM307A

10. Connect the engine ground wire to the engine; then

connect the starter positive wire to the starter using

the existing hardware. Tighten securely.

KM319A

11. Connect the coolant temperature sensor; then con-

nect the trigger coil connector, shift position connec-

tor, and stator connector.

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KM324A

KM347A

12. Install the coil (see Electrical System).

13. Install the carburetor (see Fuel/Lubrication/Cooling).

14. Install the muffler assembly (see Steering/Frame).

15. Install the gas tank and air filter (see Fuel/Lubrica-

tion/Cooling).

16. Install the fenders and front rack; then install the side

panels (see Steering/Frame).

17. Install the battery; then connect the positive and neg-

ative battery cables.

18. Pour in the recommended amount and grade of

engine coolant, engine oil, and transmission lubri-

cant.

19. Start the engine and allow it to warm up; then check

all fluid levels and add as required.

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Troubleshooting

Problem: Engine will not start or is hard to start (Compression too low)

Condition Remedy

1. Valve clearance out of adjustment

2. Valve guides worn - seated poorly

3. Valves mistimed

4. Piston rings worn excessively

5. Cylinder bore worn

6. Spark plug seating poorly

7. Starter motor cranks too slowly - does not turn

1. Adjust clearance

2. Repair - replace guides

3. Adjust valve timing

4. Replace rings

5. Replace cylinder

6. Tighten plug

7. See Electrical System

Problem: Engine will not start or is hard to start (No spark)

Condition Remedy

1. Spark plug fouled

2. Spark plug wet

3. Magneto defective

4. CDI unit defective

5. Ignition coil defective

6. High-tension lead open - shorted

1. Clean - replace plug

2. Clean - dry plug

3. Replace magneto

4. Replace CDI unit

5. Replace ignition coil

6. Replace high tension lead

Problem: Engine will not start or is hard to start (No fuel reaching the carburetor)

Condition Remedy

1. Gas tank vent hose obstructed

2. Carburetor inlet needle defective

3. Fuel hose obstructed

4. Fuel screens obstructed

1. Clean vent hose

2. Replace needle

3. Clean - replace hose

4. Clean - replace inlet screen - valve screen

Problem: Engine stalls easily

Condition Remedy

1. Spark plug fouled

2. Magneto defective

3. CDI unit defective

4. Carburetor jets obstructed

5. Valve clearance out of adjustment

1. Clean plug

2. Replace magneto

3. Replace CDI unit

4. Clean jets

5. Adjust clearance

Problem: Engine noisy (Excessive valve chatter)

Condition Remedy

1. Valve clearance too large

2. Valve spring(s) weak - broken

3. Rocker arm - rocker arm shaft worn

4. Camshaft worn

1. Adjust clearance

2. Replace spring(s)

3. Replace arm - shaft

4. Replace camshaft

Problem: Engine noisy (Noise seems to come from piston)

Condition Remedy

1. Piston - cylinder worn

2. Combustion chamber carbon buildup

3. Piston pin - piston pin bore worn

4. Piston rings - ring groove(s) worn

1. Replace - service piston - cylinder

2. Clean chamber

3. Replace - service pin - bore

4. Replace rings - piston

Problem: Engine noisy (Noise seems to come from timing chain)

Condition Remedy

1. Chain stretched

2. Sprockets worn

3. Tension adjuster malfunctioning

1. Replace chain

2. Replace sprockets

3. Repair - replace adjuster

Problem: Engine noisy (Noise seems to come from crankshaft)

Condition Remedy

1. Bearing worn - burned

2. Lower rod-end bearing worn - burned

3. Connecting rod side clearance too large

1. Replace bearing

2. Replace bearing

3. Replace thrust washer(s)

Problem: Engine noisy (Noise seems to come from transmission)

Condition Remedy

1. Gears worn - rubbing

2. Splines worn

3. Primary gears worn - rubbing

4. Bearings worn

5. Bushing worn

1. Replace gears

2. Replace shaft(s)

3. Replace gears

4. Replace bearings

5. Replace bushing

Problem: Engine noisy (Noise seems to come from secondary-transmission/right-side cover)

Condition Remedy

1. Gears - shaft(s) worn

2. Bearing(s)/bushing(s) damaged

1. Replace gears - shafts

2. Replace bearing(s)/bushing(s)

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Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft)

Condition Remedy

1. Drive - driven bevel gears damaged - worn

2. Backlash excessive

3. Tooth contact improper

4. Bearing damaged

5. Gears worn - rubbing

6. Splines worn

7. Final driven shaft thrust clearance too large

1. Replace gears

2. Adjust backlash

3. Adjust contact

4. Replace bearing

5. Replace gears

6. Replace shaft(s)

7. Replace thrust washer(s)

Problem: Centrifugal clutch slipping

Condition Remedy

1. Clutch shoes worn

2. Clutch housing excessively worn

3. Drive belt slipping - worn

1. Replace shoes

2. Replace clutch housing

3. Replace drive belt

Problem: Secondary-transmission will not shift or shift back

Condition Remedy

1. Sliding dog broken - worn

2. Gearshift fork broken - worn

3. Hi/Low shift lever out of adjustment

4. Gearshift cam worn

5. Cam stopper spring weak

6. Gearshift fork shaft worn

7. Engine idle too high

8. Shift linkage out of adjustment

1. Replace dog

2. Replace fork

3. Adjust lever

4. Replace cam

5. Replace spring

6. Replace shaft

7. Adjust engine idle

8. Adjust shift linkage

Problem: Engine idles poorly

Condition Remedy

1. Valve clearance out of adjustment

2. Valve seating poor

3. Valve guides defective

4. Rocker arms - arm shaft worn

5. Magneto defective

6. CDI unit defective

7. Spark plug fouled - gap too wide

8. Ignition coil defective

9. Float out of adjustment

10. Jets obstructed

11. Pilot screw setting improper

1. Adjust clearance

2. Replace - service seats - valves

3. Replace guides

4. Replace arms - shafts

5. Replace magneto

6. Replace CDI unit

7. Adjust gap - replace plug

8. Replace ignition coil

9. Adjust float height

10. Clean jets

11. Adjust pilot screw

Problem: Engine runs poorly at high speed

Condition Remedy

1. High RPM “cut out” against RPM limiter

2. Valve springs weak

3. Valve timing out of adjustment

4. Cams - rocker arms worn

5. Spark plug gap too narrow

6. Ignition coil defective

7. Float level too low

8. Air cleaner element obstructed

9. Fuel hose obstructed

1. Shift into higher gear - decrease speed

2. Replace springs

3. Adjust timing

4. Replace cams - arms

5. Adjust gap

6. Replace ignition oil

7. Adjust float height

8. Clean element

9. Clean - prime hose

Problem: Exhaust smoke dirty or heavy

Condition Remedy

1. Oil (in the engine) overfilled - contaminated

2. Piston rings - cylinder worn

3. Valve guides worn

4. Cylinder wall scored - scuffed

5. Valve stems worn

6. Stem seals defective

7. Air cleaner element obstructed

8. Float level too high

1. Drain excess oil - replace oil

2. Replace - service rings - cylinder

3. Replace guides

4. Replace - service cylinder

5. Replace valves

6. Replace seals

7. Clean element

8. Adjust float level

Problem: Engine lacks power

Condition Remedy

1. Valve clearance incorrect

2. Valve springs weak

3. Valve timing out of adjustment

4. Piston ring(s) - cylinder worn

5. Valve seating poor

6. Spark plug fouled

7. Rocker arms - shafts worn

8. Spark plug gap incorrect

9. Carburetor jets obstructed

10. Float level out of adjustment

11. Air cleaner element obstructed

12. Oil (in the engine) overfilled - contaminated

13. Intake manifold leaking air

14. Cam chain worn

1. Adjust clearance

2. Replace springs

3. Adjust timing

4. Replace - service rings - cylinder

5. Repair seats

6. Clean - replace plug

7. Replace arms - shafts

8. Adjust gap - replace plug

9. Clean jets

10. Adjust float height

11. Clean element

12. Drain excess oil - change oil

13. Tighten - replace manifold

14. Replace cam chain

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Problem: Engine overheats

Condition Remedy

1. Carbon deposit (piston crown) excessive

2. Oil low

3. Octane low - gasoline poor

4. Oil pump defective

5. Oil circuit obstructed

6. Gasoline level (in float chamber) too low

7. Intake manifold leaking air

8. Coolant level low

9. Fan malfunctioning

10. Fan switch malfunctioning

11. Thermostat stuck - closed

12. Radiator hoses - cap damaged - obstructed

1. Clean piston

2. Add oil

3. Drain - replace gasoline

4. Replace pump

5. Clean circuit

6. Adjust float height

7. Tighten - replace manifold

8. Fill - examine system for leaks

9. Check fan fuse - replace fan

10. Replace fan switch

11. Replace thermostat

12. Clear obstruction - replace hoses

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Fuel/Lubrication/Cooling

Carburetor

0742-556

REMOVING

1. Remove the seat; then remove the gas tank (see Gas

Tank in this section).

2. Remove the cap screws securing the air filter hous-

ing to the frame; then loosen the clamp securing air

inlet boot to the carburetor and remove the air filter.

KM320A

3. Remove the choke assembly from the carburetor

leaving the choke cable attached to the choke

plunger.

KC0018

4. Remove the screw securing the throttle actuator

cover to the carburetor; then remove the cover.

PR154B

5. Remove the throttle cable from the actuator arm.

PR162C

6. Loosen the outer jam nut securing the throttle cable

to the carburetor body; then route the cable out of the

way.

! WARNING

Whenever any maintenance or inspection is performed

on the fuel system during which there may be fuel leak-

age, there should be no welding, smoking, open flames,

etc., in the area.

KEY

1. Screw

2. Top

3. Spring

4. Seat, Spring

5. Jet Needle

6. Vacuum Piston

7. Needle Jet

8. Needle Jet Holder

9. Main Jet

10. Starter Valve

11. Coil Spring

12. Cap

13. O-Ring

14. Cable

15. Tube

16. Pilot Screw

17. O-Ring

18. Float Arm Pin

19. Float

20. O-Ring

21. Slow Jet

22. Drain Screw

23. Float Valve

24. Float Valve Clip

25. Float Chamber

26. Screw

27. Clip

28. Drain Tube

29. Spring

30. Washer

31. Washer

32. Spring

33. Idle Adjust Screw

34. Top Cover

35. Screw

36. Starter Jet

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PR162B

7. Disconnect the vent hose; then remove the carbure-

tor.

DISASSEMBLING

1. Remove the four Phillips-head screws securing the

top cover; then remove the cover.

KC0019A

2. Remove the vacuum piston assembly from the carbu-

retor body. Account for a spring, spring seat, and the

jet needle.

KC0021A

3. Remove the Phillips-head screws securing the float

chamber; then remove the chamber. Account for the

O-ring.

KC0022A

KC0063A

4. Remove the float pin.

KC0024A

5. Lift the float assembly from the carburetor. Account

for the float valve.

CC753

NOTE: Note the locations of the jets, pilot screw,

and holder for disassembling procedures.

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CC761A

6. Secure the needle jet holder with a wrench; then

remove the main jet.

KC0030A

7. Remove the needle jet holder; then remove the nee-

dle jet, slow jet, and the starter jet.

8. Remove the pilot screw. Account for a spring,

washer, and an O-ring.

CC758

CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is nec-

essary.

1. Place all metallic components in a wire basket and

submerge in carburetor cleaner.

2. Soak for 30 minutes; then rinse with clean, hot water.

3. Wash all non-metallic components with soap and

water. Rinse thoroughly.

4. Dry all components with compressed air only mak-

ing sure all holes, orifices, and channels are unob-

structed.

5. Inspect the carburetor body for cracks, nicks,

stripped threads, and any imperfections in the cast-

ing.

6. Inspect the vacuum piston for cracks, imperfections

in the casting, or cracks and tears in the rubber.

7. Inspect float for damage.

8. Inspect gasket and O-rings for distortion, tears, or

noticeable damage.

9. Inspect tips of the jet needle, pilot screw, and the

needle jet for wear, damage, or distortion.

10. Inspect the slow jet and main jet for obstructions or

damage.

NOTE: If the slow jet is obstructed, the mixture will

be extremely lean at idle and part-throttle operation.

11. Inspect the float valve for wear or damage.

12. Inspect the carburetor mounting flange for damage

and tightness.

ASSEMBLING

1. Install the pilot screw, spring, washer, and O-ring.

CC758

NOTE: Turn the pilot screw clockwise until it is

lightly seated; then turn it counterclockwise the rec-

ommended number of turns as an initial setting.

NOTE: Note the locations of the jets and holder dur-

ing assembling procedures.

! WARNING

When drying components with compressed air, always

wear safety glasses.

CAUTION

DO NOT place any non-metallic components in parts-

cleaning solvent because damage or deterioration will

result.

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CC761A

2. Install the slow jet. Tighten securely.

3. Install the main jet into the needle jet holder and

tighten securely; then install the needle jet, starter jet,

and needle jet holder assembly into the carburetor

and tighten securely.

4. Place the float assembly (with float valve) into posi-

tion and secure to the carburetor with the float pin.

CC753

NOTE: Check float arm height by placing the carbu-

retor on its side w/float contacting the needle; then

measure with a caliper the height when the float arm

is in contact with the needle valve. Float arm height

should be 17 mm.

5. Place the float chamber into position making sure the

O-ring is properly positioned; then secure with the

Phillips-head screws.

KC0063A

KC0022A

6. Place the jet needle, spring seat, and spring into the

vacuum piston; then place the assembly down into

the carburetor.

7. Place the top cover into position; then secure with

the Phillips-head screws. Tighten securely.

KC0019A

INSTALLING

1. Connect the vent hose onto the carburetor.

2. Place the throttle cable into position and secure by

tightening the outer jam nut.

PR162B

3. Connect the throttle cable to the actuator arm.

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PR162C

4. Place the throttle actuator cover into position on the

carburetor; then secure with the screw.

PR154B

5. Connect the choke assembly to the carburetor.

6. Install the air filter; then tighten the clamp securing

the air inlet boot to the carburetor. Secure the air fil-

ter housing to the frame with the cap screws.

7. Install the gas tank; then install the seat.

Throttle Cable Free-Play

To adjust throttle cable free-play, use the following pro-

cedure.

1. Slide the rubber boot away from the adjuster; then

loosen the jam nut (1) from the throttle cable adjuster

(2).

KM111A

2. Turn the adjuster until the throttle cable has proper

free-play of 1-4 mm (1/16-3/16 in.) at the lever.

ATV-0047B

3. Tighten the jam nut against the throttle cable adjuster

securely; then slide the rubber boot over the adjuster.

Engine RPM (Idle)

To properly adjust the idle RPM, a tachometer is neces-

sary. To adjust idle RPM, use the following procedure.

NOTE: The idle adjustment screw is located on the

right side of the carburetor.

1. With the transmission in neutral, start the engine and

warm it up to normal operating temperature.

2. Turn the idle adjustment screw clockwise one turn

past the recommended RPM setting; then turn it

counterclockwise to the correct setting of 1250-1350

RPM.

Gas Tank

REMOVING

1. Turn the gas tank valve to the OFF position.

2. Remove the seat.

3. Disconnect the hose from the carburetor to the gas

tank at the tank connection.

4. Cut the tie-down securing the gas hose to the cables

and hoses.

5. Remove the cap screws securing the gas tank to the

frame.

! WARNING

Adjust the idle to the correct RPM. Make sure the engine

is at normal operating temperature before adjusting the

idle RPM.

! WARNING

Whenever any maintenance or inspection is made on

the fuel system during which there may be fuel leakage,

there should be no welding, smoking, open flames, etc.,

in the area.

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KM327A

6. Remove the vent hose; then remove the gas tank.

CLEANING AND INSPECTING



NOTE: Whenever a part is worn excessively, cracked,

or damaged in any way, replacement is necessary.

1. Clean all gas tank components with parts-cleaning

solvent.

2. Inspect all hoses for cracks or leaks.

3. Inspect gas tank valve, tank cap, and tank for leaks,

holes, and damaged threads.

4. Inspect the gas gauge for proper operation.

INSTALLING

1. Place the gas tank into position on the frame; then

install the cap screws. Tighten securely.

2. Connect the gas hose from the carburetor; then

secure hose to cables and hoses with a cable tie.

3. Install the vent hose; then fill the gas tank with gaso-

line.

4. Turn the gas tank valve to the ON position and

inspect for leakage.

5. Install the seat.

Gas Tank Valve

The ATV has a valve attached to the gas tank. There are

three positions: ON, RES, and OFF.

KM043A

In the OFF position, the valve will not allow gasoline to

flow to the carburetor. In the ON position (the normal

operating position), gasoline will flow from the tank to

the carburetor. In this position, 4.54 L (1.2 U.S. gal.) will

remain in the tank as a reserve quantity. Moving the

valve to the RES position will allow the operator to use

the remaining gasoline in the tank. When turning the

valve to any of the three positions, make sure the indica-

tor is pointed directly at the position desired.

REMOVING/INSPECTING

1. Remove the gas hose from the valve by releasing the

clamp.

2. Remove the two machine screws securing the valve;

then remove the valve. Account for the gasket.

3. Inspect the gasket and valve/tank mating surfaces for

damage or deterioration.

4. Inspect for and remove any obstructions in the valve.

INSTALLING

1. Place the valve and gasket into position on the tank

and secure with the machine screws. Tighten securely.

2. Install the gas hose onto the valve with the clamp.

Gas/Vent Hoses

Replace the gas hose every two years. Damage from

aging may not always be visible. Do not bend or obstruct

the routing of the carburetor vent hose. Make sure the

vent hose is securely connected to the carburetor and the

opposite end is always open.

Oil Flow Chart

KM427A

! WARNING

Drain the gas tank prior to this procedure.

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Oil Pump

NOTE: Whenever internal engine components wear

excessively or break and whenever oil is contami-

nated, the oil pump should be disassembled,

cleaned, and inspected.

NOTE: The oil pump is not a serviceable compo-

nent. If the pump is defective, the oil pump must be

replaced.

REMOVING/DISASSEMBLING

1. Remove the oil pump from the engine (see Right-

Side Components in Engine/Transmission).

2. Remove the Phillips-head screw on the back side of

the pump and separate the pump housing and cover.

Note the position of the inner and outer rotors and

alignment pin for assembly.

3. Remove oil pump components.

CLEANING AND INSPECTING

NOTE: If any part is worn excessively, cracked, or

damaged in any way, the oil pump must be replaced.

1. Clean all oil pump components.

2. Inspect the rotors for scoring and gouges.

3. Inspect the alignment pin, driveshaft, and driven

sprocket for damage.

4. Inspect the pump housing and cover for cracks or

damage.

ASSEMBLING/INSTALLING

1. Place the rotors into the pump housing making sure

the alignment pin is in the groove of the rotor.

2. Place the cover onto the pump housing.

3. Secure the pump with the Phillips-head screw coated

with red Loctite #271.

4. Install the oil pump into the engine (see Right-Side

Components in Engine/Transmission).

Liquid Cooling System

When filling the cooling system, use pre-mixed Arctic

Cat Antifreeze. While the cooling system is being filled,

air pockets may develop; therefore, run the engine for

five minutes after the initial fill, shut the engine off, and

fill the coolant overflow tank under the seat to the FULL

line.

KM136A

Radiator

REMOVING

1. Drain the coolant at the engine.

KM314A

2. On the Utility, remove the front rack; then remove

the front cover and fender assembly (see Steering/

Frame).

3. Remove the upper and lower coolant hoses.

4. Remove the cap screws and nuts securing the radia-

tor to the frame.

5. Disconnect the fan wiring from the main wiring har-

ness; then remove the radiator/fan assembly and

account for the grommets and collars.

6. Remove the fan/fan shroud assembly from the radiator.

CLEANING AND INSPECTING



NOTE: Whenever a part is worn excessively, cracked,

or damaged in any way, replacement is necessary.

1. Flush the radiator with water to remove any contami-

nants.

2. Inspect the radiator for leaks and damage.

3. Inspect all hoses for cracks and deterioration.

4. Inspect all fasteners and grommets for damage or

wear.

CAUTION

After operating the ATV for the initial 5-10 minutes, stop

the engine, allow the engine to cool down, and check

the coolant level. Add coolant as necessary.

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INSTALLING

1. Position the fan/fan shroud assembly on the radiator;

then secure with existing hardware.

2. Place the radiator with grommets and collars into

position on the frame; then install the cap screws and

nuts. Tighten securely.

3. Install the upper and lower coolant hoses; then

secure with hose clamps.

4. On the Utility, install the front cover and fender

assembly; then install the front rack (see Steering/

Frame).

5. Fill the cooling system with the recommended

amount of antifreeze. Check for leakage.

6. Connect the fan wiring to the main wiring harness.

7. Start the engine and run for 3-5 minutes; then check

coolant level in the radiator and in the coolant overflow

tank and add as required to the appropriate levels.

KM339A

KM136A

8. On the Utility, install the cover and rack (see Steering/

Frame).

Hoses/Thermostat

REMOVING

1. Drain approximately one U.S. qt of coolant from the

cooling system.

2. Remove the two machine screws securing the ther-

mostat housing cover to the thermostat housing.

Account for an O-ring and a thermostat.

INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is nec-

essary.

1. Inspect the thermostat for corrosion, wear, or spring

damage.

2. Using the following procedure, inspect the thermo-

stat for proper operation.

A. Suspend the thermostat in a container filled with

water.

B. Heat the water and monitor the temperature with a

thermometer.

C. The thermostat should start to open at 78-82° C

(172-179° F) and should be full-open at 90° C

(194° F).

D. If the thermostat does not open, it must be

replaced.

3. Inspect all coolant hoses, connections, and clamps

for deterioration, cracks, and wear.

NOTE: All coolant hoses and clamps should be

replaced every four years or 4000 miles.

INSTALLING

1. Place the thermostat and O-ring into the thermostat

housing; then secure the thermostat housing cover to

the thermostat housing with the two cap screws.

Tighten securely.

2. Fill the cooling system with the recommended

amount of antifreeze. Check for leakage.

Fan

REMOVING

1. Remove the radiator (see Radiator in this section).

2. Remove the fan assembly from the radiator.

INSTALLING

1. Position the fan assembly on the radiator; then secure

with existing hardware.

2. Install the radiator (see Radiator in this section).

Water Pump

REMOVING/DISASSEMBLING

1. Drain the coolant.

2. Remove the four cap screws securing the water

pump case. Account for the gasket and two align-

ment pins.

3. Remove the impeller, washer, and seal washer.

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4. Remove the mechanical seal using the following pro-

cedure.

A. Tap the tip of a small sheet metal screw into the

inner-metal edge of the seal.

B. Grip the screw with a pair of vise-grip pliers and

pull the seal out. Account for the pump drive seal.

CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is nec-

essary.

1. Clean all pump components in parts-cleaning sol-

vent.

2. Inspect the mechanical seal and pump drive seal for

damage.

NOTE: If the mechanical seal and/or pump drive

seal are damaged, they must be replaced as a set.

3. Inspect the impeller for corrosion or damage.

ASSEMBLING/INSTALLING

NOTE: Treat seals and O-rings with clean antifreeze

for initial lubrication.

1. Press the seal washer into the impeller by hand.

2. Install the water pump drive seal; then drive the

mechanical seal into the crankcase cover using an

appropriate seal driver.

3. Install the impeller with seal washer onto the water

pump shaft and tighten securely.

4. Place the water pump case into position and secure

with the four cap screws.

5. Fill the cooling system with the recommended

amount of antifreeze.

NOTE: While the cooling system is being filled, air

pockets may develop; therefore, run the engine for

five minutes after the initial fill, shut the engine off,

and then fill the cooling system.

6. Check the entire cooling system for leakage.

Troubleshooting

Problem: Starting impaired

Condition Remedy

1. Starter jet obstructed

2. Starter jet passage obstructed

3. Starter body - carburetor leaking air

4. Starter valve not operating properly

1. Clean jet

2. Clean passage

3. Tighten - adjust - replace gasket

4. Check - adjust valve

Problem: Idling or low speed impaired

Condition Remedy

1. Slow jet obstructed - loose

2. Slow jet outlet obstructed

3. Low speed fuel screw setting incorrect

4. Starter valve not fully closed

5. Float height incorrect

1. Clean - tighten jet

2. Clean outlet

3. Adjust screw

4. Adjust valve

5. Adjust float height

Problem: Medium or high speed impaired

Condition Remedy

1. High RPM “cut out” against RPM limiter

2. Main jet obstructed

3. Needle jet obstructed

4. Throttle vacuum piston not operating properly

5. Filter obstructed

6. Float height incorrect

7. Starter valve not fully closed

1. Shift into higher gear - decrease RPM speed

2. Clean main jet

3. Clean needle jet

4. Check piston operation

5. Clean filter

6. Adjust float height

7. Adjust valve

Problem: Overflow and fuel level fluctuations

Condition Remedy

1. Float valve worn - damaged

2. Float valve spring broken

3. Float not working properly

4. Float valve dirty

5. Float height too high - too low

1. Replace valve

2. Replace spring

3. Adjust float height - replace float

4. Clean valve

5. Adjust float height

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Electrical System

This section has been organized into sub-sections which

show procedures for the complete servicing of the Arctic

Cat ATV electrical system.

SPECIAL TOOLS

A number of special tools must be available to the techni-

cian when performing service procedures in this section.

Refer to the current Special Tools Catalog for the appro-

priate tool description.

NOTE: Special tools are available from the Arctic

Cat Service Parts Department.

RPM Limiter

NOTE: The ATV is equipped with a CDI unit that

retards ignition timing when maximum RPM is

approached. When the RPM limiter is activated, it

could be misinterpreted as a high-speed misfire.

Testing Electrical

Components

All of the electrical tests should be made using the Fluke

Model 77 Multimeter and when testing peak voltage, the

Peak Voltage Reading Adapter must be used. If any other

type of meter is used, readings may vary due to internal

circuitry. When troubleshooting a specific component,

always verify first that the fuse(s) are good, that the

bulb(s) are good, that the connections are clean and tight,

that the battery is fully charged, and that all appropriate

switches are activated.

NOTE: For absolute accuracy, all tests should be

made at room temperature of approximately 68° F.

Electrical Connections

The electrical connections should be checked periodi-

cally for proper function. In case of an electrical failure,

check fuses, connections (for tightness, corrosion, dam-

age), and/or bulbs.

Switches

Each time the ATV is used, switches should be checked

for proper operation. Use the following list for reference.

A. Ignition switch — engine will start.

B. Emergency stop switch — engine will stop.

C. Reverse switch — reverse indicator light will illu-

minate.

D. Hi/Lo switch — headlight high beam or low beam

will illuminate.

E. Brake switches — rear brakelight will illuminate.

Battery

The battery is located under the seat (DVX) or behind the

seat (Utility).

After being in service, batteries require regular cleaning

and recharging in order to deliver peak performance and

maximum service life. The following procedure is rec-

ommended for cleaning and maintaining a sealed battery.

Always read and follow instructions provided with bat-

tery chargers and battery products.

1. Remove the battery hold-down; then disconnect the

battery cables (negative cable first).

2. Remove the battery from the battery compartment;

then thoroughly wash the battery and battery com-

partment with soap and water.

NOTE: If battery posts, cable ends, or the battery

case has a build-up of white/green powder residue,

apply water and baking soda to neutralize acid; then

flush off with warm soapy water.

3. Using a wire brush, clean the battery posts and cable

ends removing all corrosive buildup. Replace dam-

aged cables or cable ends.

4. Using a multimeter, test the battery voltage. The

meter must read at least 12.5 DC Volts for a fully

charged battery.

NOTE: At this point if the meter reads as specified,

the battery may be returned to service (see step 8).

Description p/n

Fluke Model 77 Multimeter 0644-559

MaxiClips 0744-041

Peak Voltage Reading Adapter 0644-307

Tachometer 0644-275

Timing Light 0644-296

! WARNING

Any time service is performed on a battery, the following

must be observed: keep sparks, open flame, cigarettes, or

any other flame away. Always wear safety glasses. Protect

skin and clothing when handling a battery. When servicing

battery in enclosed space, keep the area well-ventilated.

CAUTION

Do not remove seal strip.

! WARNING

Battery acid is harmful if it contacts eyes, skin, or cloth-

ing. Care must be taken whenever handling a battery.

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5. If the meter reads less than specified voltage, charge

the battery using the following guidelines.

A. When using an automatic battery charger, always

follow the charger manufacturer’s instructions.

B. When using a constant-current battery charger,

use the following Battery Charging Chart.

NOTE: If the battery voltage is 11.5 DC Volts or less,

some chargers may “cut off” and fail to charge. If this

occurs, connect a fully charged booster battery in

parallel (positive to positive and negative to negative)

for a short period of time with the charger connected.

After 10-15 minutes, disconnect the booster battery

leaving the charger connected and the charger

should continue to charge. If the charger “cuts off,”

replace the battery.

6. After charging the battery for the specified time,

remove the battery charger and allow the battery to

sit for 1-2 hours.

7. Connect the multimeter and test the battery voltage.

The meter should read at least 12.5 DC Volts. If the

voltage is as specified, the battery is ready for ser-

vice.

NOTE: If voltage in step 7 is below specifications,

charge the battery an additional 1-5 hours; then

retest.

8. Place the battery in the battery compartment; then

coat the battery posts and cable ends with a light coat

of multi-purpose grease.

9. Connect the battery cables (positive cable first); then

install the battery hold-down.

Brakelight Switch

(Auxiliary)

The switch connector is the two-prong white connector

on the right side of the engine directly above the switch.



NOTE: The ignition switch must be in the ON position.

VOLTAGE (Wiring Harness Side)

1. Set the meter selector to the DC Voltage position.

2. Connect the red tester to the brown/blue wire; then

connect the black tester lead to ground.

3. The meter must show battery voltage.

NOTE: If the meter shows no battery voltage, trou-

bleshoot the battery, fuse, switch, or the main wiring

harness.

NOTE: If the meter shows battery voltage, the main

wiring harness is good; proceed to test the switch/

component, the connector, and the switch wiring har-

ness for resistance.

RESISTANCE (Switch Connector)

1. Set the meter selector to the OHMS position.

2. Connect the red tester lead to the brown/blue wire; then

connect the black tester lead to the green/yellow wire.

3. When the brake pedal is depressed, the meter must

show less than 1 ohm.

NOTE: If the meter shows more than 1 ohm of resis-

tance, replace the switch.

Brakelight Switch

(Handlebar Control)

The switch has spade-type connectors which engage the

harness connectors at the switch.



NOTE: The ignition switch must be in the ON position.

VOLTAGE (Wiring Harness

Connector)

1. Set the meter selector to the DC Voltage position.

2. Connect the red tester lead to the brown/blue wire;

then connect the black tester lead to ground.

3. The meter must show battery voltage.

NOTE: If the meter shows no battery voltage, trou-

bleshoot the battery, fuse, switch, or the main wiring

harness.

NOTE: If the meter shows battery voltage, the main

wiring harness is good; proceed to test the switch/

component, the connector, and the switch wiring har-

ness for resistance.

CAUTION

Never exceed the standard charging rate.

! WARNING

An overheated battery could explode causing severe

injury or death. Always monitor charging times and

charge rates carefully. Stop charging if the battery

becomes very warm to the touch. Allow it to cool before

resuming charging.

Battery Charging Chart (Constant-Current Charger)

Battery Voltage

(DC)

Charge

State

Charge Time Required

(at 1.5-2.0 Amps)

12.5 or more 100% None

12.2-12.4 75%-99% 3-6 hours

12.0-12.2 50%-74% 5-11 hours

11.0-11.9 25%-49% 13 hours (minimum)

11.5 or less 0-24% 20 hours (minimum)

CAUTION

Before installing the battery, make sure the ignition

switch is in the OFF position.

CAUTION

Connecting cables in reverse (positive to negative and

negative to positive) can cause serious damage to the

electrical system.

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RESISTANCE (Switch)

NOTE: The brake lever must be compressed for this

test. Also, the ignition switch must be in the OFF

position.

1. Set the meter selector to the OHMS position.

2. Connect the red tester lead to one spade terminal;

then connect the black tester lead to the other spade

terminal.

3. When the lever is compressed, the meter must show

less than 1 ohm.

NOTE: If the meter shows more than 1 ohm of resis-

tance, replace the switch.

Coolant Temperature and

Cooling Fan Switches

1. Connect the meter leads (selector in the OHMS posi-

tion) to the switch contacts.

2. Suspend the switch and a thermometer in a container

of cooking oil; then heat the oil.

NOTE: Neither the switch nor the thermometer

should be allowed to touch the bottom of the con-

tainer or inaccurate readings will occur. Use wire

holders to suspend switch and thermometer.

733-554E

3. On the cooling fan switch when the temperature

reaches 86-90° C (187-194° F), the meter should

read a closed circuit. On the coolant temperature sen-

sor when the temperature reaches 120° C (218° F),

the meter should read 16.0 ohms.

4. Allow the oil to cool. On the cooling fan switch

when the temperature is within a range of 80-85° C

(176-185° F), the meter should read an open circuit.

On the coolant temperature sensor, monitor the tem-

perature and resistance as the oil cools. At 100° C

(212° F) the meter should read 27 ohms, at 80° C

(176° F) 52 ohms, and at 50° C (122° F) 154 ohms.

5. If the readings are not as indicated, the switch must

be replaced.

6. Install the switch and tighten securely.

7. Connect the switch leads.

Fan Motor

The fan motor connector is located directly above the

fan. To access the connector on the Utility, the front rack

and front center cover must be removed (see Steering/

Frame).



NOTE: The ignition switch must be in the ON position.

VOLTAGE (Main Harness

Connector to Fan Motor)

1. Set the meter selector to the DC Voltage position.

2. Connect the red tester lead to the brown/blue wire;

then connect the black tester lead to ground.

3. The meter must show battery voltage.



NOTE: If the meter shows no battery voltage, trouble-

shoot the battery, fuse, or the main wiring harness.

NOTE: If the meter shows battery voltage, the main

wiring harness is good. The connector should be

checked for resistance.

RESISTANCE (Fan Motor

Connector)

1. Set the meter selector to the OHMS position.

2. Connect the red tester lead to the blue wire; then con-

nect the black tester lead to the black wire.

3. The meter must show 50-60 ohms.

NOTE: If the meter does not show as specified, trou-

bleshoot or replace the connector or the fan.

NOTE: To determine if the fan motor is good, con-

nect the blue wire from the fan connector to a 12 volt

DC power supply; then connect the black wire from

the fan connector to ground. The fan should operate.

Fuse Block

The fuses are located in a fuse block under the seat.

If there is any type of electrical system failure, always

check the fuses first.

NOTE: To remove a fuse, compress the locking tabs

on either side of the fuse case and lift out.

! WARNING

Care should be taken to keep clear of the fan blades.

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KM102

NOTE: The ignition switch must be in the LIGHTS

position.

1. Remove all fuses from the fuse block.

2. Set the meter selector to the DC Voltage position.

3. Connect the black tester lead to ground.

4. Using the red tester lead, contact each end of the 30

amp fuse holder connector terminals individually.

5. The meter must show battery voltage from one side

of the connector terminal ends.

6. Install the 30 amp fuse; then using the red tester lead,

check the remaining two fuse holder connectors as in

step 4.

NOTE: Battery voltage will be indicated from only

one side of the fuse holder connector terminal; the

other side will show no voltage.



NOTE: If the meter shows no battery voltage, trouble-

shoot the battery, fuse block, or the main wiring harness.

Fuses

1. Set the meter selector to the OHMS position.

2. Connect the red tester lead to one spade end of the

fuse; then connect the black tester lead to the other

spade end.

AR610D

3. The meter must show less than 1 ohm resistance. If

the meter reads open, replace the fuse.

NOTE: Make sure the fuses are returned to their

proper position according to amperage. Refer to the

fuse block cover for fuse placement.

Ignition Coil

The ignition coil is on the left side of the frame above the

engine. To access the coil on the Utility, the left side

panel must be removed (see Steering/Frame).

PEAK VOLTAGE (Primary/CDI Side)

NOTE: All of the peak voltage tests should be made

using the Fluke Model 77 Multimeter with Peak Volt-

age Reading Adapter. If any other type of tester is

used, readings may vary due to internal circuitry.



NOTE: The battery must be at full charge for these tests.

NOTE: The ignition switch must be in the ON posi-

tion; the emergency stop switch must be in the RUN

position. Also, the white/blue wire must be discon-

nected from the coil.

1. Set the meter selector to the DC Voltage position.

2. Connect the red tester lead to the black/white wire; then

connect the black tester lead to the green/gray wire.

3. The meter reading must be within specifications.

NOTE: If the voltage is not as specified in the above

test, inspect the main wiring harness, main fuse, igni-

tion fuse, ignition switch, or engine stop switch.

RESISTANCE

NOTE: For these tests, the meter selector must be

set to the OHMS position.

Primary Winding

1. Remove the two spade connectors from the coil; then

connect the red tester lead to either terminal and the

black tester lead to the other terminal.

2. The meter reading must be within specification.

Secondary Winding

1. Connect the red tester lead to the high tension lead

(plug cap removed); then connect the black tester

lead to ground.

2. The meter reading must be within specification.

NOTE: If the meter does not show as specified,

replace ignition coil.

Spark Plug Cap

1. Connect the red tester lead to one end of the cap; then

connect the black tester lead to the other end of the cap.

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AR603D

2. The meter reading must be within specification.

NOTE: If the meter does not read as specified,

replace the spark plug cap.

Indicator Lights (DVX)

To access the indicator lights, use the following proce-

dure.

1. Remove the two cap screws and one reinstallable

rivet securing the instrument pod; then turn the

instrument pod over to access the indicator lights.

2. Remove the light to be tested by pulling the bulb

socket from the light pod; then remove the bulb from

the socket.

NOTE: Bulbs must be checked by switching to a

position where the bulb is illuminated. Power to the

indicator light may be verified by installing a working

light bulb in that position.

LCD Gauge Assembly

REMOVING

To remove the LCD gauge assembly, see Steering/Frame.

TESTING

NOTE: If any functions (segments or displays) are

not normal or do not display as indicated, the LCD

gauge must be replaced.

1. Remove the instrument pod; then disconnect the

speedometer cable. Leave the gauge connected to the

wiring harness.

NOTE: To perform the following tests, two MaxiClips

and one jumper wire will be required.

2. Connect the black MaxiClip to the green/black wire.

3. Connect the red MaxiClip to the light green/red wire;

then connect the jumper between the MaxiClips and

turn the ignition switch to the ON position. The neu-

tral indicator light (9) must illuminate.

KM123D

4. Connect the red MaxiClip to the blue/red wire. The

reverse indicator light (10) must illuminate.

5. Connect the red MaxiClip to the white/red wire. The

low range light (3) must illuminate.

6. Connect the red MaxiClip to the green/blue wire.

The temperature indicator (4) must indicate hot (all

indicator segments visible) and begin flashing. The

thermometer icon will also flash.

7. Connect the red MaxiClip to the yellow/white wire.

The fuel quantity indicator (8) must sequence (one

segment every 8-10 seconds) until the bottom seg-

ment begins flashing. After flashing for 8-10 sec-

onds, the bottom segment will extinguish and the gas

pump icon (7) will begin flashing.



NOTE: There must be sufficient gas in the gas tank to

illuminate at least one fuel quantity indicator segment.

8. Connect the red MaxiClip to the blue wire; then con-

nect a voltmeter to the MaxiClips (red meter lead to

red and black meter lead to black).

9. Set the meter selector to the DC Voltage position;

then turn the ignition switch to the LIGHTS position

and the light control switch to the HI beam position.

The tester must indicate battery voltage and the high

beam indicator light (15) must illuminate. If the tes-

ter does not read battery voltage, troubleshoot the

ignition switch, light control switch, or wiring har-

ness and connectors.

10. Connect the red MaxiClip to the brown/black wire.

The tester must read battery voltage and the speed-

ometer backlight (5) must illuminate. If the tester

does not read battery voltage, troubleshoot the igni-

tion switch or wiring harness connectors.

11. Depress and hold the Mode/Set button (1). The

speedometer should switch between mph and km/h

as indicated by icon (12).

12. Depress and hold the Mode/Set button (2). The dis-

tance mode should shift between ODO and TRIP as

indicated by icon (12).

13. Depress and hold the Mode/Set buttons (1) and (2)

simultaneously. The hour segment of the clock

should flash indicating the clock (13) is in the set

mode. Release the Mode/Set button (2) and release

when the desired hour (1-24) appears.

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14. Depress and release the Mode/Set button (1) to shift

the clock set to the minute segment; then depress

Mode/Set button (2) to set the desired minute.

NOTE: In the clock set mode, the gauge will default

to normal operation 10 seconds after the Mode/Set

buttons are released.

15. With the ignition switch in the ON position, use a

small screwdriver or suitable tool to spin the input

quill of the speedometer. The speed indicator (6)

must indicate a value greater than zero.

INSTALLING

To install the LCD gauge assembly, see Steering/Frame.

Ignition Switch

The connector is the white one beneath the front cover.

To access the connector on the Utility, the front rack and

front cover must be removed (see Steering/Frame).

VOLTAGE

NOTE: Perform this test on the lower side of the

connector.

1. Set the meter selector to the DC Voltage position.

2. Connect the red meter lead to the red/white wire;

then connect the black meter lead to ground.

3. The meter must show battery voltage.

NOTE: If the meter shows no battery voltage, trou-

bleshoot the battery, 30 amp fuse, or the main wiring

harness.

RESISTANCE

NOTE: Perform this test on the upper side of the

connector.

1. Turn the ignition switch to the ON position.

2. Set the meter selector to the OHMS position.

3. Connect the red tester lead to the red wire; then con-

nect the black tester lead to the black wire.

4. The meter must show less than 1 ohm.

5. Turn the ignition switch to the LIGHTS position.

6. Connect the red tester lead to the red wire; then con-

nect the black tester lead to the brown wire.

7. The meter must show less than 1 ohm.

NOTE: If the meter shows more than 1 ohm of resis-

tance, replace the switch.

Handlebar Control

Switches

Two white connectors join the handlebar control switch

pigtails to the main harness. To access the connectors on

the Utility, the front rack and front cover must be

removed (see Steering/Frame).



NOTE: These tests should be made on the switch

side of the connectors with the connectors uncoupled.

RESISTANCE (HI Beam)

1. Set the meter selector to the OHMS position.

2. Connect the red tester lead to the blue wire; then con-

nect the black tester lead to the brown/black wire.

3. With the dimmer switch in the HI position, the meter

must show less than 1 ohm.

NOTE: If the meter shows more than 1 ohm of resis-

tance, troubleshoot or replace the switch/component

or the connector.

RESISTANCE (LO Beam)

1. Connect the red tester lead to the white wire; then

connect the black tester lead to the brown/black wire.

2. With the dimmer switch in the LO position, the

meter must show less than 1 ohm.

NOTE: If the meter reads more than 1 ohm of resis-

tance, troubleshoot or replace the switch/component

or the connector.

RESISTANCE (Starter Button)

1. Set the meter selector to the OHMS position.

2. Connect the red tester lead to the black/white wire;

then connect the black tester lead to the yellow/red

wire.

3. With the starter button depressed, the meter must

show less than 1 ohm.

4. With the starter button released, the meter must show

an open circuit.

NOTE: If the meter does not show as specified,

replace the switch/component or connector.

RESISTANCE (Emergency Stop)

1. Set the meter selector to the OHMS position.

2. Connect the red tester lead to the brown/blue wire;

then connect the black tester lead to the black/white

wire.

3. With the switch in the OFF position, the meter must

show an open circuit.

4. With the switch in the RUN position, the meter must

show less than 1 ohm.

NOTE: If the meter shows more than 1 ohm of resis-

tance, troubleshoot or replace the switch/component

or the connector.

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RESISTANCE (Reverse Override)

1. Set the meter selector to the OHMS position.

2. Connect the red tester lead to the green/red wire;

then connect the black tester lead to the blue/red

wire. The meter must show an open circuit.

3. Depress and hold the reverse override button. The

meter must show less than 1 ohm of resistance.

NOTE: If the meter does not show as specified,

replace the switch/component or connector.

Magneto Coils

VOLTAGE (Charging Coil - Output)

1. Set the meter selector to the DC Voltage position.

2. Connect the red tester lead to the positive battery

post; then connect the black tester lead to the nega-

tive battery post.

3. With the engine running at a constant 5000 RPM

(with the headlights on), the meter must show 14-

15.5 DC volts.

NOTE: If voltage is lower than specified, test stator

coil - no load.

VOLTAGE (Stator Coil - No Load)

The connector is the black and white one on the right side

of the engine just above the brake cable adjuster.

NOTE: Test the connector that comes from the

engine.

1. Set the meter selector to the AC Voltage position.

2. Test between the three yellow wires for a total of

three tests.

3. With the engine running at the specified RPM, all

wire tests must show as specified.

NOTE: If both voltage tests failed, check all connec-

tions, etc., and test again. If no voltage is present,

replace the stator assembly.

RESISTANCE (Charging Coil)

1. Set the meter selector to OHMS position.

2. Test between the three yellow wires for a total of

three tests.

3. The meter reading must be within specification.

RESISTANCE (Trigger Coil)

1. Set the meter selector to the OHMS position.

2. Connect the red tester lead to the blue/yellow wire;

then connect the black tester lead to the green/white

wire. The meter reading must be within specification.

PEAK VOLTAGE

NOTE: All of the peak voltage tests should be made

using the Fluke Model 77 Multimeter with Peak Volt-

age Reading Adapter. If any other type of tester is

used, readings may vary due to internal circuitry.



NOTE: The battery must be at full charge for these tests.

Stator Coil (Trigger)

1. Set the meter selector to the DC Voltage position.

2. Connect the red tester lead to the blue/yellow wire;

then connect the black tester lead to the green/white

wire.

3. Crank the engine over using the electric starter.

4. The meter reading must be within specification.

Starter Motor

NOTE: The starter motor is not a serviceable com-

ponent. If the starter motor does not operate, see

Starter Relay in this section. If the relay tests normal,

replace the starter motor.

REMOVING/INSTALLING

1. Disconnect the battery.

2. Remove the nut securing the positive cable to the

starter; then remove the cable from the starter.

3. Remove the two cap screws securing the starter to

the crankcase; then remove the starter. Account for

the wiring forms and an O-ring.

4. Install the new starter motor.

Starter Relay

VOLTAGE

1. Set the meter selector to the DC Voltage position.

2. Connect the red tester lead to the battery supply ter-

minal (1); then connect the black lead to the starter

terminal (2).

CAUTION

Do not run the engine at high RPM for more than 10 sec-

onds.

CAUTION

Do not run the engine at high RPM for more than 10 sec-

onds.

CAUTION

Always disconnect the negative battery cable from the

battery first; then disconnect the positive cable.

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KM458A

3. Turn the ignition switch to the ON position. The

meter must read battery voltage.

NOTE: If battery voltage is not shown on the meter,

troubleshoot the battery connections, ground con-

nections, and starter cable connections.

4. With the transmission in neutral, depress the starter

button. There should be an audible “click” from the

starter relay and the meter should show 0 DC volts.

If the meter indicates as specified, replace the starter.

If there is no audible click and meter reads battery

voltage, proceed to step 5.

5. Disconnect the two-wire connector on the starter

relay pigtail from the main harness; then on the har-

ness side, connect the red tester lead to the yellow/

red wire and the black tester lead to the yellow/green

wire.

6. With the transmission in neutral, depress the starter

button. The meter must read battery voltage. If bat-

tery voltage is indicated, replace the starter solenoid.

If no voltage is indicated, troubleshoot the gear posi-

tion switch, starter button, ignition switch, or harness

connectors.

CDI Unit

The CDI is located beneath the seat near the battery.

NOTE: The CDI unit is not a serviceable component.

If the unit is defective, it must be replaced.

The CDI is rarely the cause for electrical problems; how-

ever, if the CDI is suspected, substitute another CDI unit

to verify the suspected one is defective.

NOTE: Prior to replacing the CDI unit to assure the

CDI unit is defective, it is advisable to perform a CDI

peak voltage test (see Ignition Coil in this section)

and/or perform a continuity test of the wiring harness

from the CDI connector to the CDI unit.

Regulator/Rectifier

The regulator/rectifier is located on the right side of the

frame. Verify all other charging system components

before the regulator/rectifier is replaced.

TESTING

1. Start the engine and warm up to normal operating

temperature; then connect a multimeter to the battery

as follows.

2. Select the DC Voltage position; then connect the red

tester lead to the positive battery post and the black

tester lead to the negative battery post.

3. Start the engine and slowly increase RPM. The volt-

age should increase with the engine RPM to a maxi-

mum of 15.5 DC volts.

NOTE: If voltage rises above 15.5 DC volts, the reg-

ulator is faulty or a battery connection is loose or cor-

roded. Clean and tighten battery connections or

replace the regulator/rectifier. If voltage does not rise,

check Voltage (Stator Coil - No Load) sub-section. If

charging coil voltage is normal, replace the regulator/

rectifier.

Start-in-Gear Relay

NOTE: The relay schematic is embossed on the

relay housing for testing continuity.

NOTE: The module and wiring harness are not a

serviceable component and must be replaced as an

assembly.

TESTING

The start-in-gear relay is located under the seat below the

fuse block. To test the relay, use the following procedure.

1. Turn the ignition switch to the ON position; then

compress the brake lever or depress the auxiliary

brake pedal. There should be an audible “click” from

the start-in-gear relay.



NOTE: The brakelight should illuminate whenever

either brake is applied. If the brakelight does not illumi-

nate, troubleshoot the respective brakelight switch.

2. Apply the opposite brake from step 1. There should

be an audible “click” from the start-in-gear relay.

3. Disconnect the four-wire connector from the start-in-

gear relay; then using a voltmeter, connect the red

tester lead to the green/yellow wire (1) and the black

tester lead to the green wire (3).

KM460A

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4. With the ignition switch in the ON position, select

the DC volts position on the tester; then apply either

brake. The meter must read battery voltage. If battery

voltage is observed and no audible “click” was heard

in step 1 or 2, remove the tester leads and replace the

start-in-gear relay.

5. Shift the gear selector out of neutral and connect a

jumper wire between the yellow/green wire (2) and

the green wire (4).

KM460A

6. Momentarily depress the starter button. The starter

should engage. If the starter engages, replace the

start-in-gear relay. If the starter does not engage,

troubleshoot the battery connections, starter relay, or

starter connections.

Headlights

On the Utility, the connectors are the two 3-prong ones

secured to the front bumper supports (one on each side)

with cable ties.

On the DVX, the connectors are the two 3-prong ones

under the front fender.

BULB VERIFICATION (LO and HI

Beam)

Visually inspect the bulb for broken filaments, blacken-

ing, or loose bulb base.

VOLTAGE



NOTE: Perform this test in turn on the main harness

side of the connectors. Also, the ignition switch must be

in the LIGHTS position and the engine must be running.

1. Set the meter selector to the DC Voltage position.

2. Connect the red tester lead to the green wire; then

connect the black tester lead to the white wire.

3. With the dimmer switch in the LO position (LO

beam), the meter must show battery voltage.

4. Connect the red tester lead to the blue wire. With the

dimmer switch in the HI position (HI beam), the

meter must show battery voltage.

NOTE: If battery voltage is not shown in any test,

inspect the fuses, battery, main wiring harness, con-

nectors, or the left handlebar switch.

Taillight - Brakelight

The connector is the 3-prong one located under the rear

fender assembly.

BULB VERIFICATION

Visually inspect the bulb for broken filaments, blacken-

ing, or loose bulb base.

VOLTAGE (Taillight)

NOTE: Perform this test on the main harness side of

the connector. Also, the ignition switch should be in

the LIGHTS position.

1. Set the meter selector to the DC Voltage position.

2. Connect the red tester lead to the brown/black wire;

then connect the black tester lead to the green wire.

3. With the ignition key in the LIGHTS position, the

meter must show battery voltage.

NOTE: If the meter shows no voltage, inspect fuses,

wiring harness, connectors, and switches.

VOLTAGE (Brakelight)

NOTE: Perform this test on the main harness side of

the connector. Also, the ignition switch should be in

the ON position and the brake (either foot pedal or

hand lever) must be applied.

1. Set the meter selector to the DC Voltage position.

2. Connect the red tester lead to the green/yellow wire;

then connect the black tester lead to the green wire.

3. With either brake applied, the meter must show bat-

tery voltage.

NOTE: If the meter shows no voltage, inspect fuses,

wiring harness, connectors, and switches.

Ignition Timing

The ignition timing cannot be adjusted; however, verify-

ing ignition timing can aid in troubleshooting other com-

ponents. To verify ignition timing, use the following

procedure.

1. Attach the Timing Light to the spark plug high ten-

sion lead; then remove the timing inspection plug

from the left-side crankcase cover.

2. Using the Tachometer, start the engine and run at

1000 RPM; ignition timing should be 5° BTDC (“F”

mark).

3. Install the timing inspection plug.

If ignition timing cannot be verified, the rotor may be

damaged, the key may be sheared, the trigger coil bracket

may be bent or damaged, or the CDI unit may be faulty.

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Troubleshooting

Problem: Spark absent or weak

Condition Remedy

1. Ignition coil defective

2. Spark plug defective

3. Magneto defective

4. CDI unit defective

5. Pick-up coil defective

1. Replace ignition coil

2. Replace plug

3. Replace magneto

4. Replace CDI unit

5. Replace pick-up coil

Problem: Spark plug fouled with carbon

Condition Remedy

1. Mixture too rich

2. Idling RPM too high

3. Gasoline incorrect

4. Air cleaner element dirty

5. Spark plug incorrect (too cold)

6. Valve seals cracked - missing

7. Oil rings worn - broken

1. Adjust carburetor

2. Adjust carburetor

3. Change to correct gasoline

4. Clean element

5. Replace plug

6. Replace seals

7. Replace rings

Problem: Spark plug electrodes overheat or burn

Condition Remedy

1. Spark plug incorrect (too hot)

2. Engine overheats

3. Spark plug loose

4. Mixture too lean

1. Replace plug

2. Service cooling system

3. Tighten plug

4. Adjust carburetor

Problem: Magneto does not charge

Condition Remedy

1. Lead wires/connections shorted - loose - open

2. Magneto coils shorted - grounded - open

3. Regulator/rectifier defective

1. Repair - replace - tighten lead wires

2. Replace magneto coils

3. Replace regulator/rectifier

Problem: Magneto charges, but charging rate is below the specification

Condition Remedy

1. Lead wires shorted - open - loose (at terminals)

2. Stator coils (charging) grounded - open

3. Regulator/rectifier defective

4. Cell plates (battery) defective

1. Repair - tighten lead wires

2. Replace stator coils

3. Replace regulator/rectifier

4. Replace battery

Problem: Magneto overcharges

Condition Remedy

1. Internal battery short circuited

2. Regulator/rectifier defective

3. Regulator/rectifier poorly grounded

1. Replace battery

2. Replace regulator/rectifier

3. Clean - tighten ground connection

Problem: Charging unstable

Condition Remedy

1. Lead wire intermittently shorting

2. Magneto internally shorted

3. Regulator/rectifier defective

1. Replace lead wire

2. Replace magneto

3. Replace regulator/rectifier

Problem: Starter button not effective

Condition Remedy

1. Battery charge low

2. Switch contacts defective

3. Starter motor brushes not seating

4. Starter relay defective

5. Emergency stop - ignition switch off

6. Wiring connections loose - disconnected

7. Starter bushings worn

8. Starter armature shorted - open

9. Brake switch defective

1. Recharge - replace battery

2. Replace switch

3. Repair - replace brushes

4. Replace relay

5. Turn on switches

6. Connect - tighten - repair connections

7. Replace starter

8. Replace starter

9. Replace switch

Problem: Battery “sulfation” (Acidic white powdery substance or spots on surfaces of cell plates)

Condition Remedy

1. Charging rate too low - too high

2. Specific gravity too low

3. Battery run-down - damaged

4. Electrolyte contaminated

1. Replace battery

2. Charge battery

3. Replace battery

4. Replace battery

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Problem: Battery discharges too rapidly

Condition Remedy

1. Electrolyte contaminated

2. Specific gravity too high

3. Battery short-circuited

4. Specific gravity too low

1. Replace battery

2. Check charging

3. Replace battery

4. Recharge battery

Problem: Battery polarity reversed

Condition Remedy

1. Battery incorrectly connected

2. Electrical system damaged

1. Reverse connections - replace battery

2. Replace damaged components

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Drive System

SPECIAL TOOLS

A number of special tools must be available to the techni-

cian when performing service procedures in this section.

Refer to the current Special Tools Catalog for the appro-

priate tool description.

NOTE: Special tools are available from the Arctic

Cat Service Parts Department.

Rear Drive Assembly

Schematics

KM462

KM463

Rear Drive Axle (DVX)

REMOVING

1. Secure the ATV on a support stand to elevate the rear

wheels.

2. Engage the brake lever lock; then remove the

wheels.

3. Remove the hub caps; then remove and discard the

cotter pins.

KM464

4. Remove the rear wheel hubs; then remove the brake

caliper and lay aside.

NOTE: Do not apply pressure to the brake pedal

with the caliper removed. The brake piston will be

pushed out and brake fluid will be spilled.

5. Remove the two axle nuts (left-hand threads).

Account for one flat washer and a spacer.

KM471

6. Remove the brake disc assembly from the axle.

KM472

Description p/n

Pivot Lock Nut Wrench 0444-201

Rear Axle Nut Wrench 0444-198

Pinion Gear Bearing Nut Wrench 0444-203

Pinion Puller 0444-202

V Blocks 0644-535

DVX

Utility

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

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7. Loosen the drive chain (see Periodic Maintenance);

then slip the chain off the sprocket and remove the

axle assembly from the right side.

KM476A

8. Remove the cap screw from the rear brake caliper

holder; then remove the snap ring securing the cali-

per holder to the axle housing.

KM481A

9. Remove the brake caliper holder and aligning collar.

Account for the O-ring.

KM483

10. Remove the four cap screws from the rear of the

swing arm assembly; then remove the rear axle hous-

ing from the right side of the swing arm.

11. Remove the snap ring securing the driven sprocket to

the axle; then remove the sprocket.

KM477

CLEANING AND INSPECTING

1. Inspect the sprocket teeth for wear. If they are worn

as shown, replace the engine sprocket, rear sprocket,

and drive chain as a set.

ATV2185

2. Measure the rear axle runout as shown using V

blocks and a dial indicator. If the axle runout exceeds

1.5 mm (0.06 in.), the axle must be replaced.

KM480

3. Inspect the dust seals for wear or damage. If any

defect is found, replace the dust seal.

4. Inspect the axle bearings by rotating them by hand. If

any roughness, binding, or excessive looseness is

found, replace the axle bearings.

NOTE: If the axle bearings are replaced, replace the

dust seals with new ones. Always pack the bearings

with a good quality wheel bearing grease.

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Removing Bearings

1. Remove the dust seals using an appropriate seal removal

tool; then using an appropriate driver, drive the bearings

out of the axle housing. Account for one spacer.

NOTE: Do not reuse bearings after removal.

KM486

2. Clean the axle housing and inspect for cracks, elon-

gated holes, and wear in bearing bores.

Installing Bearings

1. Pack the new bearings with a good quality wheel

bearing grease; then install the right bearing first

using an appropriate bearing installer. The sealed

side of the bearing must be directed inward.

2. Install the spacer; then install the left bearing.

KM486

3. Install new dust seals and lightly coat the lips with

grease.

INSTALLING

1. Install the axle housing in the swing arm; then install

and finger-tighten the two cap screws.

KM481A

2. Install the brake caliper holder; then install the cir-

clip and cap screw and finger-tighten only.

KM482

3. Slide the axle into the axle housing from the right

side; then apply multipurpose grease to all splined

areas of the axle.

4. Install the sprocket and sprocket hub on the axle and

secure with the snap ring; then install the drive chain.

KM477

5. On the left side, install the brake disc assembly and

spacer; then install the brake caliper and secure with

the two cap screws.

NOTE: To aid in tightening the axle nuts, engage the

brake lever lock.

NOTE: It is necessary to calculate the torque value

using the following formula due to the offset of the

special tool used to tighten the axle nuts.

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6. Coat the axle threads with red Loctite #271 and

install one axle nut (left-hand threads); then using the

Rear Axle Nut Wrench, tighten the inner axle nut to

calculated specification.

KM471

T: Torque wrench reading to be calculated

Ts: Specified torque value (86 ft-lb)

Ls: Tool offset length (center to center)

L: Length of torque wrench (handle pivot to headcenter)

ATV2189

7. Install the washer; then install the outer axle nut and

tighten to calculated specification.

KM470

8. Adjust the drive chain (see Periodic Maintenance/

Tune-Up); then tighten the two cap screws.

9. Install the wheel hubs and tighten the rear wheel hub

nuts to 72 ft-lb; then install the cotter pins and hub caps.

10. Install the rear wheels and tighten to 32 ft-lb.

Rear Drive Axle (Utility)

REMOVING

1. Secure the ATV on a support stand to elevate the rear

wheels.

2. Compress the brake lever and engage the brake lever

lock; then remove the rear wheels and hub caps.

3. Remove the cotter pins and rear hub nuts; then

remove the hubs.

4. Disengage the brake lever lock; then remove the rear

brake calipers and brake disc.

NOTE: Do not apply the brakes with the calipers

removed. The brake pistons will be pushed out and

brake fluid will be spilled.

KM505

5. Remove the rear drive gear case; then drain the gear

case.

6. Loosen the clamp securing the joint boot to the

swing arm; then slip the boot off the swing arm.

KM504

7. Remove the clamp securing the brakeline hose to the

swing arm; then remove the lower rear shock

absorber mounting nut and bolt.

L x Ts = T

L + Ls

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

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KM505

8. Remove the left and right pivot caps; then remove

the right-side pivot bolt.

KM506

9. From the left side, remove the pivot lock nut using

Pivot Lock Nut Wrench; then remove the left pivot

adjusting bolt.

KM533B

10. Remove the swing arm assembly. Account for the

driveshaft spring.

KM508

11. Disengage the universal joint from the transmission

output shaft splines and set the driveshaft aside.

KM509

12. Remove the eight cap screws securing the swing arm

to the final drive gear case.

KM513

13. Support the swing arm from the right side; then using

a rubber mallet, drive the axle shaft from the swing

arm tube. Account for two O-rings.

KM536

KM537

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14. Place the right end (shorter length) of the axle on a

wood block; then using a rubber mallet, drive the

gear case from the axle.

KM538

CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is nec-

essary.

1. Clean all parts with parts-cleaning solvent and dry

with compressed air.

2. Inspect all seals for nicks, tears, or deterioration.

KM519

3. Inspect all splines and hubs for excessive wear,

chips, cracks, or distortion.

KM539

KM540

4. Check that all bearings turn freely and smoothly and

are not worn, discolored, or missing dust seals.

5. Inspect brake components for leaks, excessive wear,

or discoloration.

6. Check the axle shaft for runout using a dial indicator

and suitable supports. Maximum runout is 3 mm

(0.12 in.).

NOTE: Axle runout is equal to 1/2 the total dial indi-

cator reading.

KM543

7. Check the final drive gear case assembly for smooth

gear operation. If gears are noisy or if there is any

catching or binding, the gear case assembly must be

repaired.

DISASSEMBLING

1. Remove the cap screws securing the gear case cover

to the gear case; then remove the gear case cover and

right ring gear shim.

KM918

CAUTION

Support the gear case by hand or damage to the gear

case could occur as it will fall free once it clears the

splined portion of the axle.

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KM919A

2. Remove the oil seal from the front of the gear case;

then using the Pinion Gear Bearing Nut Wrench,

remove the pinion nut.

KM920A

KM921

3. Remove the pinion shaft using the pinion puller; then

using a three-jaw puller, remove the pinion bearing.

Account for the pinion shim.

KM922

KM923

KM924A

4. Remove the oil seals from the case and cover; then

drive the bearings out of the case.

KM925

KM926

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KM927

KM928

5. Heat the gear case to approximately 180° F and using

a blind-bushing puller, remove the pinion needle

bearing.

CLEANING AND INSPECTING

1. Clean all components in parts cleaning solvent and

dry with compressed air.

2. Inspect all bearings for excessive wear, discolor-

ation, roughness in turning, or flaking.

3. Inspect gears for excessive wear, chipped teeth, flak-

ing, or discoloration.

4. Inspect the gear case and cover for cracks, warpage,

or scoring of bearing bores.

5. If seals have not been removed and will be reused,

inspect for nicks, tears, missing tension springs, or

excessive wear on lips.

ASSEMBLING

1. Drive the bearings into the gear case and gear case

cover using an appropriate bearing driver. Make sure

the bearing is firmly seated.

KM926

KM928

2. Apply grease to the seal lips; then using a seal driver,

drive the seals into the gear case and cover (flat side

out) until flush with the seal bore.

KM927A

KM925A

3. Drive a new pinion needle bearing into the gear case;

then apply molybdenum disulfide grease to the nee-

dle bearing. Secure with the snap ring.

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4. If the pinion bearing was removed from the pinion,

install the shim and bearing on the pinion shaft with

the marked-side of the bearing directed toward the

front of the pinion shaft.

KM924

KM935

NOTE: When the gear set, ring gear, ring gear bear-

ing, and/or gear case is being replaced, use a 2 mm

(0.08 in.) thick shim for initial set-up.

5. Drive the pinion assembly into the gear case seating

the bearing firmly; then secure with a new lock nut

and using the pinion lock nut wrench, tighten to 72

ft-lb.

KM920A

KM921

6. Apply grease to the pinion seal lips and install into

the gear case until fully seated; then apply a light

coating of machinist’s layout dye or paste to several

ring gear teeth.

7. Install the proper shims on the ring gear and install

into the gear case; then install the case cover and

secure with the case cap screws. Tighten in a criss-

cross pattern while rotating the pinion gear.

Checking Tooth Contact

1. Rotate the ring gear several turns in either direction;

then check gear contact through the oil filler hole.

2. Examine the tooth contact pattern in the dye and

compare the pattern to the illustrations.

ATV-0103

ATV-0105

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ATV-0104

Correcting Tooth Contact

NOTE: If tooth contact pattern is comparable to the

correct pattern illustration, no correction is neces-

sary.

If tooth contact pattern is comparable to an incorrect pat-

tern, correct tooth contact according to the following

chart.

After tooth contact is corrected, gear backlash must be

checked.

Checking Backlash

1. Mount a dial indicator through the oil fill plug to

contact a tooth on the ring gear; then “zero” the dial

indicator.

KM936

2. While locking the pinion shaft to prevent it from

turning, rock the ring gear back and forth and record

the measurement. Standard backlash should be 0.05-

0.25 mm (0.002-0.010 in.). Maximum service limit

is 0.4 mm (0.016 in.).

3. Remove the dial indicator and rotate the ring gear

120°; then repeat steps 1-2.

4. Repeat step 3 for a total of three measurements; then

compare the difference between the three. Maximum

allowable difference is 0.2 mm (0.08 in.).

NOTE: If the difference in measurements exceeds

specifications, the bearings are not installed squarely

or the gear case is warped. If backlash is not within

specifications, correct using the following chart.

NOTE: Always change both shims by the same

amount on opposite sides. If left shim is increased,

right shim must be decreased by the same amount.

5. After backlash is corrected, recheck gear tooth con-

tact. Repeat Correcting Tooth Contact and Checking

Backlash until both are within specifications.

6. When tooth contact and backlash are within specifi-

cation, remove the cap screws securing the cover to

the gear case.

7. Clean any oil from the mating surfaces; then apply

an even coat of silicone sealant to the mating sur-

faces and install the gear case covers.

8. Install six 8 mm and two 10 mm cap screws and

while rotating the pinion gear, tighten in a crisscross

pattern to the specified torque (8 mm cap screws to

19 ft-lb, 10 mm cap screws to 36 ft-lb).

REPLACING SWING ARM SEALS

AND BEARINGS

To replace damaged or worn seals and bearings in the

swing arm assembly, use the following procedure.

1. Remove the dust seals from the swing arm pivot;

then using a slide hammer and bearing puller,

remove the pivot bearings.

KM521

2. Drive in new pivot bearings until fully seated; then

install new dust seals.

KM522

Tooth Contact Shim Correction

Contacts at Top Decrease Shim Thickness

Contacts at Root Increase Shim Thickness

Backlash Ring Gear Left Side Ring Gear Right Side

Insufficient Decrease Shim Increase Shim

Excessive Increase Shim Decrease Shim

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3. Remove the three cap screws, the dust plate, and one

O-ring from the left axle housing on the swing arm;

then from the right side, drive out the axle bearing.

KM523A

4. Using a suitable bearing driver, install the new axle

bearing into the axle housing; then install the O-ring

and dust plate. Tighten the three cap screws securely.

INSTALLING

1. Install new O-rings in the grooves of the gear case;

then grease the center splines of the axle and install

in the gear case from the left side.

KM527

2. Install the rear axle and gear case into the right side

of the swing arm; then secure the gear case to the

swing arm assembly with the eight cap screws.

Tighten to 50 ft-lb.

KM528A

3. Apply grease to the universal joint splines and drive-

shaft splines; then install the driveshaft spring into

the driveshaft.

KM529

NOTE: Apply a liberal amount of grease to the drive-

shaft splines and the driveshaft spring. This will aid

in keeping the spring in position while assembling.

4. Insert the driveshaft assembly into the swing arm

tube; then engage the driveshaft splines with the pin-

ion shaft splines in the rear drive gear case.

KM530

5. Pack approximately 3 g (0.1 oz) of grease into each

swing arm pivot bearing cavity; then apply grease to

the lips of the dust seals.

KM531

6. Align the swing arm assembly in the frame and

engage the universal joint onto the splines of the sec-

ondary driven bevel gear shaft.

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KM532

7. Install the right pivot bolt and left pivot adjusting

bolt and tighten securely; then move the swing arm

up and down to seat the bearings. Tighten the left

pivot bolt to 36 in.-lb and the right pivot bolt to 82 ft-

lb.

8. Install the left pivot lock nut; then while holding the

left pivot adjusting bolt, use Pivot Lock Nut Wrench

to tighten the lock nut to 82 ft-lb.

KM533B

9. Install the shock absorber using the existing hard-

ware and tighten to 29 ft-lb; then install the brakeline

hose clamp on the swing arm and tighten securely.

KM505A

10. Tighten the final drive gear case drain plug securely;

then remove the fill plug and level plug.

KM131A

11. Pour the recommended gear lubricant into the fill

hole until lubricant is visible on the threads of the

level hole; then install the level plug and the fill plug

and tighten securely.

12. Install the rear drive gear case guard and tighten the

cap screws securely.

13. Apply grease to the brake disc hub and wheel hubs;

then install the disc and rear hubs.

KM502

14. Install the hub nuts and tighten to 72 ft-lb; then

install new cotter pins and bend as shown.

KM469

15. Install the rear brake calipers and tighten to 25 ft-lb.

16. Install the rear hub caps; then install the rear wheels

and tighten to 32 ft-lb.

17. Remove the ATV from the support stand.

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Troubleshooting

Drive System

Troubleshooting

Brake System

Problem: Power not transmitted from engine to wheels

Condition Remedy

1. Rear axle shaft serration worn - broken 1. Replace shaft

Problem: Braking poor

Condition Remedy

1. Pad worn

2. Pedal free-play excessive

3. Brake fluid leaking

4. Hydraulic system entrapped air

5. Master cylinder/brake cylinder seal worn

1. Replace pads

2. Adjust free-play

3. Repair - replace hydraulic system

4. Bleed hydraulic system

5. Replace appropriate cylinder

Problem: Brake lever travel excessive

Condition Remedy

1. Hydraulic system entrapped air

2. Brake fluid low

3. Brake fluid incorrect

4. Piston seal - cup worn

1. Bleed hydraulic system

2. Add fluid to proper level/bleed system

3. Replace with correct fluid

4. Replace master cylinder

Problem: Brake fluid leaking

Condition Remedy

1. Connection joints loose

2. Hose cracked

3. Piston seal worn

1. Tighten joint

2. Replace hose

3. Replace master/brake cylinder

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Suspension

The following suspension system components should be

inspected periodically to ensure proper operation.

A. Shock absorber rods not bent, pitted, or damaged.

B. Rubber damper not cracked, broken, or missing.

C. Shock absorber body not damaged, punctured, or

leaking.

D. Shock absorber eyelets not broken, bent, or

cracked.

E. Shock absorber eyelet bushings not worn, deterio-

rated, cracked, or missing.

F. Shock absorber spring not broken or sagging.

Front and Rear

Suspension Assembly

Schematics

KM598E

KM463

KM462

Front Shock Absorbers

REMOVING

1. Secure the ATV on a support stand to elevate the

wheels and to release load on the suspension.

2. Remove the cap screws and nuts securing each shock

absorber to the A-arm and frame.

KM573A

CLEANING AND INSPECTING



NOTE: Whenever a part is worn excessively, cracked,

or damaged in any way, replacement is necessary.

1. Clean the shock absorbers in parts-cleaning solvent.

2. Inspect each shock rod for nicks, pits, bends, and

oily residue.

3. Inspect the springs, spring retainers, shock rods, shock

bodies, and eyelets for cracks, leaks, and bends.

INSTALLING

1. Install each shock absorber to the frame and A-arm

with cap screws and nuts. Tighten all nuts to 29 ft-lb.

2. Remove the ATV from the support stand.

Utility

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

CAUTION

Do not tighten the nut beyond the recommended speci-

fication or the shock eyelet or mount WILL be damaged.

DVX

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Rear Shock Absorber

REMOVING

1. Secure the ATV on a support stand to elevate the

wheels and to release load on the suspension.

2. Remove the rear shield plate from the swing arm; then

remove the lower shock mounting nut and cap screw.

KM551A

NOTE: Support the swing arm with a block of wood

or other support to allow removal of the cap screw.

KM555A

3. Remove the upper shock mounting nut and cap screw;

then remove the shock absorber from the frame.

KM554

CLEANING AND INSPECTING

1. Clean the shock absorber in parts-cleaning solvent.

2. Inspect the shock absorber body, bottom stop, and

rubber bushing for damage and leaking oil. If any

defects are found, replace the shock absorber.

3. Inspect the spring, spring seat, and preload adjust-

ment nuts and threads for damage or corrosion. If

corrosion is present on the threads, clean with a fine

wire brush and oil lightly.

KM561A

INSTALLING

1. Raise the swing-arm and place the shock absorber in

position; then install the upper and lower cap screws

and nuts.

2. Tighten the upper nut and the lower nut to 29 ft-lb.

3. Install the rear swing arm skid plate and four cap

screws. Tighten securely.

ADJUSTING SPRING PRELOAD

The rear spring preload is adjustable by changing the

spring set length. Using the following procedure, adjust

the spring.

1. Loosen the lock nut (1). Adjust the spring preload by

turning the adjuster (2) clockwise to increase spring

preload or counterclockwise to decrease spring pre-

load.

KM551B

2. Tighten the lock nut securely.

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

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Swing Arm

REMOVING AND DISASSEMBLING

For the Utility, see Rear Drive Axle in Drive System. For

the DVX, use the following procedure.

1. Secure the ATV on a support stand to elevate the

wheels and to release load on the suspension.

2. Remove the rear wheels; then remove the rear hub

caps and hub nuts. Discard the cotter pins.

3. Remove the rear axle assembly (see Drive System);

then remove the rear shock absorber.

4. Remove the cushion arm lock nut and cap screw;

then remove the lock nut and cap screw securing the

cushion arm link to the swing arm. Remove the cush-

ion arm/link assembly. Account for three bushings.

KM557A

KM568A

5. Remove the axle housing (see Drive System).

6. Remove the brake hose guide clamp.

KM495

7. Remove the swing-arm pivot nut; then remove the

swing-arm pivot flange bolt and remove the swing

arm.

KM496

8. Remove the chain guide.

9. Remove the dust seals from the swing arm; then

remove two bushings and the swing arm axle.

KM499B

KM500

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

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100

10. Remove the lock nut and cap screw securing the

cushion link to the cushion arm. Account for a bush-

ing.

CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is nec-

essary.

1. Inspect the dust seals, bushings, and pivot axle for

wear or damage. If any defect is found, they must be

replaced.

2. To inspect the swing arm and swing arm axle, place

the swing arm axle and bushings in the swing arm;

then using the flange bolt, rock the bushings and axle

from side to side and up and down. If excessive play

is noted, the bushings, axle, or swing arm must be

replaced. Check for cracks or broken welds.

3. To inspect the cushion arm bushings, install the

bushings in the cushion arm; then check for exces-

sive play by rocking the bushing.

KM564A

4. Inspect the needle bearings for missing rollers, rust

or corrosion, or flat rollers. Check for a tight fit in

boss. Replace the arm if bearings are loose.

KM565

5. Inspect all dust seals and replace if they are cracked,

torn, dried out, or loose.

KM499B

KM564B

6. Inspect the drive chain and sprockets for excessive

wear, chain stiffness, or rust/corrosion.

ATV2185

ASSEMBLING AND INSTALLING

1. Remove any nicks or burrs from the bearing bosses

in the cushion arm with fine emory cloth; then using

a suitable bearing installer, press new needle bear-

ings into the end bosses of the cushion arm.

KM565A

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101

2. If the bushing was removed from the middle boss of

the cushion arm, press in a new bushing.

NOTE: The bearings and bushing must be centered

in the bearing boss so the dust seals can be properly

installed.

3. Using an appropriate seal driver, install the new dust

seals in the cushion arm; then apply multi-purpose

grease to the bearings, bushing, and dust seal lips.

4. Install the bushings in the cushion arm and cushion link;

then connect the cushion link to the cushion arm with

the flange cap screw and lock nut. Tighten securely.

KM568

5. Install the swing arm axle and bushings; then install

the dust seals and lubricate the lips with grease.

6. Place the swing arm into position in the frame; then

install the swing arm pivot cap screw and lock nut.

Tighten to 50 ft-lb.

KM496A

7. Apply grease to the swing arm pivot through the

grease fitting.

KM501

8. Place the cushion arm and cushion arm/link assem-

bly into position and secure with the flange cap

screws and new lock nuts. Tighten securely.

KM557A

9. Install the shock absorber and secure with the exist-

ing hardware. Tighten to 29 ft-lb.

10. Install the axle housing, axle, and brake assembly

(see Drive System).

11. Install the drive chain and sprockets (see Drive Sys-

tem); then adjust the chain to specifications (see

Periodic Maintenance/Tune-Up).

12. Apply grease to the axle splines; then install the hubs

and hub nuts. Tighten to 72 ft-lb.

KM468

13. Install new cotter pins; then install the hub caps and

rear wheels. Tighten the lug nuts to 32 ft-lb.

KM469

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102

KM464

14. Remove the ATV from the support stand.

Front A-Arms

REMOVING

1. Secure the ATV on a support stand to elevate the

front wheels; then remove a front wheel.

2. Remove the hub cap; then remove the cotter pin from

the nut.

SP366

3. Remove the nut securing the hub.

4. Remove the cap screws securing the brake caliper;

then remove the caliper and lay aside.

KM266A

5. Remove the hub assembly; then on the Utility,

remove the disc cover.

KM569

6. Remove the cotter pin and slotted nut securing the tie

rod end to the knuckle; then remove the tie rod end

from the knuckle.

KM573

7. Remove the brake hose clamp from the A-arm; then

remove the cotter pins and slotted nuts securing the

upper and lower ball joints.

KM570

8. Remove the shock absorber mounting cap screws;

then remove the shock absorber assembly.

9. Using a ball joint remover, remove the ball joints

from the knuckle; then remove the front bumper.

CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is nec-

essary.

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

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103

1. Clean the knuckle in parts-cleaning solvent; then dry

with compressed air. If any damage or excessive

wear is detected, the knuckle must be replaced.

2. Inspect the ball joint for boot damage or wear.

Replace the A-arm if the ball joint is damaged or

worn.

3. Inspect the arm for broken welds, cracks, or bends.

Replace if damaged.

4. Remove the bushings and dust seals and inspect for

damage to seal lips and spacers.

NOTE: The pivots are equipped with roller bearings.

The bearing rollers may fall out when the spacers are

removed.

5. Check the bearings for excessive wear and replace

them if worn.

6. Using a suitable bearing remover, remove the pivot

bearings; then clean all parts in parts-cleaning sol-

vent.

SP382

NOTE: All bearings, bushings, and seals that are

removed must be replaced with new ones.

INSTALLING

1. Install the bearings in the upper arm pivot to a depth

of 13.6 mm (0.535 in.) with a bearing installer and

suitable spacer.

ATV2196A

2. Coat the spacers and the lips of the dust seals with

multi-purpose grease; then install them in the upper

pivot.

3. Repeat steps 1 and 2 for the lower A-arm.

4. Clean all grease from the ball joint tapers and the

knuckle bores; then install the arms to the steering

knuckle and tighten the ball joint nuts to 22 ft-lb.

Install new cotter pins.

SP388A

NOTE: During assembly, new cotter pins should be

installed.

SP390

5. Install the arms to the frame with the pivot cap

screws; then tighten the nuts to 32 ft-lb.

KM579

6. Install the front bumper assembly; then install the

front shock absorbers. Apply red Loctite #271 on the

cap screw threads and tighten to 29 ft-lb.

7. On the Utility, apply red Loctite #271 to the mount-

ing cap screws; then install the disc cover and tighten

securely.

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104

KM569

8. Connect the tie rod ends to the steering knuckle; then

tighten the nut to 15 ft-lb and install a new cotter pin.

NOTE: During assembly, new cotter pins should be

installed.

KM581

Wheels and Tires

TIRE SIZE

The ATV is equipped with low-pressure tubeless tires of

the size and type listed. Do not under any circumstances

substitute tires of a different type or size.

TIRE INFLATION PRESSURE

Tire inflation pressure should be as specified.

REMOVING

1. Secure the ATV on a support stand to elevate the

wheels.

2. Remove the wheels.

NOTE: Keep left-side and right-side wheels sepa-

rated for installing them on their proper sides.

CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is nec-

essary.

1. Clean the wheels and hubs with parts-cleaning sol-

vent.

2. Clean the tires with soap and water.

3. Inspect each wheel for cracks, dents, or bends.

4. Inspect each tire for cuts, wear, missing lugs, and

leaks.

INSTALLING

1. Install each wheel on its hub.

NOTE: Make sure each wheel is installed on its

proper hub as noted in removing (the “rotation

arrow” must indicate forward direction of rotation).

AF612D

2. Tighten to 32 ft-lb.

CHECKING/INFLATING

1. Using an air pressure gauge, measure the air pressure

in each tire. Adjust the air pressure as necessary to

meet the recommended inflation pressure.

2. Inspect the tires for damage, wear, or punctures.

NOTE: If repair is needed, follow the instructions

found on the tire repair kit or remove the wheel and

have it repaired professionally.

! WARNING

Use only Arctic Cat approved tires when replacing tires.

Failure to do so could result in unstable ATV operation.

! WARNING

Always use the size and type of tires specified. Always

maintain proper tire inflation pressure.

! WARNING

Do not mix tire tread patterns. Use the same pattern

type on front and rear. Failure to heed warning could

cause poor handling qualities of the ATV and could

cause excessive drive train damage not covered by war-

ranty.

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

! WARNING

Do not operate the ATV if tire damage exists.

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105

NOTE: Make sure all tires are the specified size and

have identical tread pattern.

3. Check the front wheel toe-in and toe-out and adjust

as necessary (see Steering/Frame).

4. Test drive the ATV on a dry, level surface and note

any pulling to the left or right during acceleration,

deceleration, and braking.



NOTE: If pulling is noted, measure the circumference

of the front and rear tires on the pulling side. Compare

the measurements with the tires on the opposite side.

If pulling is noted during braking only, check and

adjust the brakes as necessary and recheck operation

(see Periodic Maintenance/Tune-Up).

5. Increase the air pressure in the tires with the smallest

circumference measurement until all tires are equal

in circumference.

6. Repeat steps 4-5 as necessary to ensure proper handling.

Troubleshooting

Problem: Suspension too soft

Condition Remedy

1. Spring(s) weak

2. Shock absorber damaged

1. Replace spring(s)

2. Replace shock absorber

Problem: Suspension too stiff

Condition Remedy

1. A-arm-related bushings worn or binding 1. Replace bushing

Problem: Suspension noisy

Condition Remedy

1. Cap screws (suspension system) loose

2. A-arm-related bushings worn

1. Tighten cap screws

2. Replace bushings

Problem: Rear wheel oscillation

Condition Remedy

1. Rear wheel hub bearings worn - loose

2. Tires defective - incorrect

3. Wheel rim distorted

4. Wheel hub cap screws loose

5. Axle shaft nut loose

6. Auxiliary brake adjusted incorrectly

7. Rear suspension arm-related bushing worn

8. Rear shock absorber damaged

9. Rear suspension arm nut loose

1. Replace bearings

2. Replace tires

3. Replace rim

4. Tighten cap screws

5. Tighten nut

6. Adjust brake

7. Replace bushing

8. Replace shock absorber

9. Tighten nut

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106

Steering/Frame/Controls

The following steering components should be inspected

periodically to ensure safe and proper operation.

A. Handlebar grips not worn, broken, or loose.

B. Handlebar not bent or cracked and has equal and

complete full-left and full-right capability.

C. Steering post bearing assembly/bearing housing

not broken, worn, or binding.

D. Ball joints not worn, cracked, or damaged.

E. Tie rods not bent or cracked.

F. Knuckles not worn, cracked, or damaged.

G. Cotter pins not damaged or missing.

The frame, welds, and racks should be checked periodi-

cally for damage, bends, cracks, deterioration, broken

components, and missing components.

Steering Post/Tie Rods

KM598E

REMOVING

1. On the Utility, remove the front rack and front center

panel (see Body in this section). On the DVX, pro-

ceed to step 2.

2. Remove the steering post cover (DVX) or the instru-

ment pod (Utility) (see Steering Post Cover/Instru-

ment Pod in this section); then remove the cap

screws securing the handlebar to the steering post.

Account for two handlebar holders.

KM189A

3. Lift the handlebar out of the lower handlebar holders

and lay the handlebar forward.

4. Remove the cotter pins and slotted nuts securing the

tie rod ends to the steering post arm; then disconnect

the tie rods from the arm.

KM590

5. Remove the cotter pin and slotted nut from the lower

end of the steering post; then remove the upper steer-

ing shaft support block. Account for a cable guide,

two steering support blocks, and the upper steering

post bushing.

KM588

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107

KM589

6. Remove the steering post from the ATV.

CLEANING AND INSPECTING



NOTE: Whenever a part is worn excessively, cracked,

or damaged in any way, replacement is necessary.

1. Wash the tie rod ends in parts-cleaning solvent. Dry

with compressed air. Inspect the pivot area for wear.

Apply a low-temperature grease to the ends.

2. Inspect the tie rods for damaged threads or wear.

3. Inspect the tie rods for cracks or unusual bends.

4. Inspect all welded areas for cracks or deterioration.

5. Inspect the steering post and steering-post holders

for cracks, bends, or wear.

6. Inspect the handlebar clamps for cracks or wear.

7. Inspect the handlebar for cracks, wear, or unusual

bends.

8. Inspect the handlebar grips for damage or wear.

9. Inspect the lower steering post support bearing and

seal for wear or cracks.

INSTALLING

1. Apply a thin coat of grease to the lips of the lower

steering post seals; then lower the steering post into

position in the lower steering post bearings.

KM593

2. Apply a thin coat of grease to the upper steering post

bushing; then secure the steering post with the support

blocks and existing hardware. Tighten to 17 ft-lb.

KM589

KM595

3. Install the slotted nut on the lower steering post and

tighten to 50 ft-lb; then install a new cotter pin.

KM591

4. Place the inner tie rod ends into the steering post arm

and tighten the slotted nuts to 15 ft-lb; then install

new cotter pins.

KM590

! WARNING

Always wear safety glasses when using compressed air.

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108

5. Install the handlebar and tighten the clamp cap

screws to 18 ft-lb making sure to tighten the front

cap screws first.

KM587

KM597

6. Install the instrument pod (Utility) or steering post

cover (DVX).

7. Install the center panel and front rack (Utility).

Measuring/Adjusting

Toe-In/Toe-Out

1. With the ATV on a level surface, center the handle-

bar for straight ahead using a suitable means of mea-

suring centering; then adjust tire pressure to

specifications (see General Information).

2. Support the front of the ATV with the wheels free to

rotate; then center and secure the handlebar.

3. Measure the distance (A) and (B) between the front

wheels; then subtract distance (B) from (A). Distance

A - Distance B = Toe-In.

ATV2205

4. Adjust toe-in to 15 mm (0.60 in.); then measure dis-

tances (C) and (D). Distances (C) and (D) should be

equal.

5. After all the adjustments are to specifications,

tighten the tie-rod lock nuts to 15 ft-lb.

NOTE: Prior to locking the jam nuts, make sure the

ball joints are at the center of their normal range of

motion and at the correct angle.

NOTE: The front wheels do not have to be removed

to adjust the tie rod. Also, care should be taken not to

disturb the handlebar position.

Body

REMOVING (DVX)

1. Remove the seat; then remove the battery hold-down

strap, battery, and starter relay. Lay the relay aside

without disconnecting the wiring.

NOTE: Always remove the negative battery cable

first; then the positive cable.

SP107

2. Remove the CDI, start-in-gear relay, and fuse block

and lay aside without disconnecting the wires; then

remove the shift knob.

3. Remove the six cap screws securing the body to the

top of the frame; then remove the cap screws from

the bottom of the battery box.

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109

KM782A

KM790A

4. Remove four flange nuts and cap screws securing the

rear fender support; then remove the push nuts from

the mounting studs at the front of the rear fenders.

KM785A

KM784A

5. Remove the hardware securing the front fenders to

the fender supports; then disconnect the headlight.

KM352A

6. Turn the handlebar to the left; then raise the body

turning it to the right and lift clear of the handlebar.

REMOVING (Utility)

1. Remove the seat; then remove the battery box cover.

KM793A

2. Disconnect the negative battery cable first; then the

positive cable.

3. Remove the battery hold-down strap; then remove

the battery.

4. Remove the front and rear racks; then remove the

cap screws securing the front center panel and

remove the panel.

KM308A

5. Remove the cap screws and flange nuts securing the

mud guards to the front and rear fenders; then

remove the cap screws securing the mud guards to

the front rests and remove the mud guards.

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110

KM789A

6. Remove the side panels; then remove the cap screws

and flange nuts securing the front and rear fenders to

the frame and fender supports.

KM799B

7. Disconnect the left and right headlight connectors;

then disconnect the taillight.

8. Remove the gas tank cover; then remove the shift

knob and front and rear fenders.

KM797

CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is nec-

essary.

1. Clean all body components with soap and water.

2. Inspect the body and fenders for cracks.

3. Inspect threaded areas of all mounting studs for strip-

ping.

4. Inspect for missing decals.

INSTALLING (DVX)

1. Fit the body over the handlebar and rotate into nor-

mal mounting position.

2. Using the existing hardware, secure the front fenders

to the fender supports; then connect the headlight.

3. Using the existing hardware, secure the rear fenders

to the forward fender supports; then secure the rear

fender to the frame with four cap screws and flange

nuts. Tighten securely.

4. Install the six cap screws securing the body to the top

of the frame. Tighten securely.

5. Install the fuse block, start-in-gear relay, and the

CDI; then install the body mounting cap screw into

the bottom of the battery box.

6. Install the battery and battery hold-down strap; then

connect the positive battery cable and the negative

battery cable.

NOTE: Always install the positive cable first; then

install the negative cable.

7. Install the seat making sure it is latched securely.

INSTALLING (Utility)

1. Place the front and rear fenders into position on the

frame and secure with the existing hardware; then

install the gas tank cover. Tighten all fasteners

securely.

2. Connect the headlight and taillight connectors; then

install the shift knob.

3. Making sure the locating tabs engage the appropriate

slots in the fenders, install the side panels.

KM340A

4. Install the mud guards and secure to the fenders and

foot rest supports with the existing hardware. Make

sure all locating tabs are appropriately engaged with

the fenders and side panels.

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KM789A

KM788A

5. Install the front center cover; then install the front

and rear racks. Tighten all fasteners securely.

6. Install the battery; then connect the positive battery

cable, negative battery cable, and battery hold-down

strap.

NOTE: Always install the positive cable first; then

install the negative cable.

7. Install the battery cover; then install the seat making

sure it locks securely in place.

Steering Post Cover/

Instrument Pod

REMOVING (DVX)

1. Remove the two reinstallable rivets on the rear of the

steering post cover; then lift up and push the assem-

bly forward to remove.

2. Disconnect the wire connectors from the indicator

lights and from the ignition switch.

REMOVING (Utility)

1. Remove the reinstallable rivet on the front of the

instrument pod and the two cap screws on the rear;

then lift the assembly off and disconnect the speed-

ometer cable.

2. Remove the self-tapping screw securing the LCD

gauge assembly to the instrument pod; then remove

the LCD gauge.

NOTE: The LCD gauge is not a serviceable compo-

nent. If any functions are incorrect or indicator lights

do not illuminate, the LCD gauge must be replaced.

INSPECTING/SERVICING (DVX)

1. Remove the two self-tapping screws securing the

indicator lamp assembly in the steering post cover.

2. Inspect the bulbs for blackening or burn out. Replace

as required.

3. Inspect the indicator lamp holder for loose sockets, bro-

ken wires, or loose connections. Replace as required.

INSPECTING (Utility)

The LCD gauge is not a serviceable component. To

inspect the LCD gauge, see Electrical System.

INSTALLING (DVX)

1. Connect the indicator lamp connectors; then connect

the main harness connector to the ignition switch.

2. Place the steering post cover onto the mounting

bracket; then secure with the reinstallable rivets.

INSTALLING (Utility)

1. Connect the main harness connector to the LCD

gauge; then connect the ignition harness to the igni-

tion connectors.

2. Place the instrument pod onto the mounting bracket; then

secure with the reinstallable rivet and two cap screws.

Front Brake Lever/Master

Cylinder Assembly

NOTE: The master cylinder is a non-serviceable

component; it must be replaced as an assembly.

REMOVING

1. Connect a clear hose to the bleed screw on either

front brake caliper; then open the bleed screw and

pump the brake fluid into a suitable container. Close

the bleed screw.

KM116A

CAUTION

Brake fluid is highly corrosive. Do not spill brake fluid

on any surface of the ATV.

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NOTE: Do not reuse brake fluid. When exposed to

air, brake fluid rapidly absorbs moisture.

2. Remove the brakeline hose union bolt; then remove

the cap screws securing the master cylinder assembly

to the handlebar. Discard the crush washers from the

union bolt.

KM800A

3. Remove the brake lever, brakelight switch, and brake

lever lock.

INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is nec-

essary.

1. Inspect the pivot bolt securing the brake lever for

wear.

2. Inspect the brake lever for elongation of the pivot

hole.

3. Inspect the reservoir for cracks and leakage.

4. Inspect the brake hose for cracks and deterioration

and the condition of the fittings (threaded and com-

pression).

5. Inspect the brakelight switch for corrosion, cracks,

missing or broken mounting tabs, or broken and

frayed wiring.

NOTE: If the brakelight switch is determined to be

not serviceable, see Electrical System.

INSTALLING

1. Install the brakelight switch on the master cylinder;

then install the brake lever and brake lever lock.

2. Install the master cylinder assembly on the handlebar

engaging the alignment stud in the hole in the han-

dlebar; then secure with the master cylinder clamp

and two cap screws. Make sure the UP arrow on the

clamp is directed upward.

KM800B

3. Tighten the cap screw (1) to 13 ft-lb; then tighten the

cap screw (2) to 13 ft-lb.

KM800B

4. Using new crush washers, secure the brake hose to

the master cylinder with the brake hose union bolt.

Tighten to 25 ft-lb.

KM800A

5. Fill the master cylinder with DOT 4 brake fluid; then

bleed the system (see Periodic Maintenance).

Auxiliary Brake Pedal/

Master Cylinder

Assembly

NOTE: The auxiliary brake master cylinder is a non-

serviceable component; it must be replaced as an

assembly.

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REMOVING

1. Connect a clear plastic hose to the appropriate bleed

screw on the rear brake caliper; then loosen the bleed

screw and pump the foot brake until the fluid is

pumped into a suitable container.

2. Compress the reservoir clamp and remove the reser-

voir hose; then remove the union bolt. Account for

and discard two crush washers.

KM801A

3. Remove the cotter pin from the clevis pin and

remove the clevis pin; then remove the two cap

screws securing the master cylinder to the frame and

remove the master cylinder.

KM801B

4. Loosen the jam nut; then remove the clevis and

adjuster nut.

INSTALLING

1. Install the jam nut; then install the clevis and adjuster

nut. Finger-tighten only at this time.

2. Secure the master cylinder to the frame with the two

cap screws and tighten securely.

3. Using two new crush washers, connect the brake

hose to the master cylinder with the union bolt; then

making sure the spring clamp is seated securely, con-

nect the reservoir hose to the master cylinder.

Tighten the union bolt to 25 ft-lb.

4. Making sure the brake pedal is fully released and

against the stop, turn the clevis and adjuster nut until

the hole in the clevis is aligned with the hole in the

brake pedal lever; then tighten the jam nut securely.

CD476

KM801C

5. Fill the master cylinder reservoir with DOT 4 brake

fluid and bleed the system (see Periodic Mainte-

nance/Tune-Up).

Throttle Control

REMOVING

1. Remove the boot from the throttle cable adjuster;

then loosen the jam nut and turn the adjuster com-

pletely in to loosen the cable.

2. Remove the three machine screws securing the cover

to the throttle control; then remove the cover and dis-

engage the throttle cable from the throttle arm.

3. Turn the cable adjuster out of the throttle control

housing; then remove the two machine screws secur-

ing the throttle control to the handlebar and remove

the throttle control.

INSTALLING

1. Making sure the throttle housing upper flat aligns

with the alignment mark on the handlebar, place the

throttle control into position on the handlebar and

secure with the two machine screws; then tighten the

machine screws securely.

CAUTION

Brake fluid is highly corrosive. Do not spill brake fluid

on any surface of the ATV.

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KM122B

2. Thread the throttle cable into the throttle housing and

turn the adjuster completely in; then connect the

throttle cable to the throttle arm.

3. Install the throttle housing cover; then adjust the

throttle cable (see Fuel/Lubrication/Cooling).

Troubleshooting

Problem: Handling too heavy or stiff

Condition Remedy

1. Front wheel alignment incorrect

2. Lubrication inadequate

3. Tire inflation pressure incorrect

4. Tie rod ends seizing

5. Linkage connections seizing

1. Adjust alignment

2. Lubricate appropriate components

3. Adjust pressure

4. Replace tie rod ends

5. Repair - replace connections

Problem: Steering oscillation

Condition Remedy

1. Tires inflated unequally

2. Wheel(s) wobbly

3. Wheel hub cap screw(s) loose - missing

4. Wheel hub bearing worn - damaged

5. Tie rod ends worn - loose

6. Tires defective - incorrect

7. A-arm bushings damaged

8. Bolts - nuts (frame) loose

1. Adjust pressure

2. Replace wheel(s)

3. Tighten - replace cap screws

4. Replace bearing

5. Replace - tighten tie rod ends

6. Replace tires

7. Replace bushings

8. Tighten bolts - nuts

Problem: Steering pulling to one side

Condition Remedy

1. Tires inflated unequally

2. Front wheel alignment incorrect

3. Wheel hub bearings worn - broken

4. Frame distorted

5. Shock absorber defective

1. Adjust pressure

2. Adjust alignment

3. Replace bearings

4. Repair - replace frame

5. Replace shock absorber

Problem: Steering impaired

Condition Remedy

1. Tire pressure too high

2. Steering linkage connections worn

3. Cap screws (suspension system) loose

1. Adjust pressure

2. Replace connections

3. Tighten cap screws

Problem: Tire wear rapid or uneven

Condition Remedy

1. Wheel hub bearings worn - loose

2. Front wheel alignment incorrect

1. Replace bearings

2. Adjust alignment

Problem: Steering noise

Condition Remedy

1. Cap screws - nuts loose

2. Wheel hub bearings broken - damaged

3. Lubrication inadequate

1. Tighten cap screws - nuts

2. Replace bearings

3. Lubricate appropriate components

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Arctic_cat_2012_dvx_300_300_utility_service_manual Arctic Cat 2012 Dvx 300 Utility Service Manual

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